Home

A THERMADYNE® Company PAK MASTER

1. 18 ON OFF RUN SET DEMAND AC TEMP__PIP GAS oc PILOT E fs fs fs fs La La J1 ESEESE J um A FRONT PANEL SWITCHES amp LEDS SOL FF 3 219 pes DER NOTE TO BYPASS LOGIC AND GET D C POWER 18 JUMPER TP21 ENABLE TO TP3 GND perl lass 19 Pat GAS 11 22 23 LOGIC DRIVER DISPLAY ES 420787 SCHEMATIC le 19X1864 ASSEMBLY POWER 114x147 PCB oe i 19 START 24 28 25 17 PIP 26 18 27 B J5 J2 GATE DRIVE amp RAIL VOLTAGE J8 SENSING 48 PIN RIBBON if 24 3f 4 a FILTER BOARD 19 18 zz zz CA 420786 SCH J18 oo ao gt 19X837 ASSEMBLY 3 on On 114x146 PCB NT NT T2 J12 313 BHH 6 QBVAC L8 77 E POWER oo T3 SUPPLY 52 SPARK Wl GAP E11 E5 P S E19 SS WE o ojo S Az is 56 DC L5 ER La 4 ES P E15 52 52 k Fr SC of 13 KE Man FET PCB m 4 hes 420798 SCHEMATIC 3 F 1 19X1 66 ASSEMBLY 25 6 T i 114x158 PCB 26 1 1 H 127 ER CC 2 mi o zen ges 59 des H B 3 ZNZ POWER E8 EBP 34 PIN SUPPLY D 4 RIBBON DC E17 CABLE 58 58 iy oS WORK 57 FAR 674 PELIE 58 12W 46 57 POWER POWER P 47 48 SLD SEN 52 56 o la o Rule lee tel 1 5 5 u
2. 1 YEAR INCLUDING BUT NOT LIMITED TO STARTING CIRCUIT CONTACTORS RELAYS SOLENOIDS PUMPS POWER SWITCHING SEMI CONDUCTORS CONSOLES CONTROL EQUIPMENT HEAT 00eieeaeeeeeeee 1 YEAR 1 YEAR 1 YEAR EXCHANGES AND ACCESSORY EQUIPMENT TORCH AND LEADS A 180 DAYS 180 DAYS 180 DAYS REPAIR REPLACEMENT PARTS AA 90 DAYS 90 DAYS wee NONE Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Arc 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 Thermal Arc is a Registered Trademark of Thermal Dynamics Effective February 1 1995 INTRODUCTION viii SECTION 1 GENERAL INFORMATION 1 1 SYSTEM DESCRIPTION The Pak Master 50 e Pak Master 50 The power supply provides 35 amp maximum Air Plasma Cutting output and includes all control circuitry electrical and gas System Includes inputs and outputs pilot circuitry and a quick disconnect torch leads receptacle The power supply is shipped with a work cable and clamp attached A 230V single phase primary input power cable with molded 50 amp
3. Cut Capacity 1 2 in 12 7 mm at 10 ipm Pilot Circuitry High Frequency HF Constant DC CNC Capability Remote Start Stop OK to Move and Corner Slowdown CSD Weight 69 8 Ibs 31 7 kg Dimensions 18 5 High x 11 1 Wide x 21 7 Long 470 x 282 x 551 mm Table 1 A Power Supply Specifications Configurations 70 or 90 Hand Torch 180 Machine Torch Current Rating 35 amps Maximum DC Straight Polarity Duty Cycle 100 35 amps Cutting Range Most materials up to 1 2 in 12 7 mm Pierce Rating 1 4 in 6 3 mm Transfer Distance 3 8 in 9 5 mm Consumable Parts Gas Distributor Electrode Tip Shield Cup Gases Compressed Air Nitrogen N2 Pressure Requirements 70 psi 4 8 BAR Flow Requirements Cutting 200 scfh 94 4 Ipm Gouging 230 scfh 108 5 lpm Available Leads Lengths GENERAL INFORMATION 12 5 ft 3 8 m 25 ft 7 2 m or 50 ft 15 2 m Extendable to 150 ft 45 6 m Table 1 B Torch Specifications 2 Manual 0 2444 1 2 SPECIFICATIONS continued 2 2 95 in 1 06 in 75 mm 27 9 59 in PEEN 244 mm K a 3 09 in
4. e Wear proper protective clothing e Make sure others in the operating area are protected from arc rays INTRODUCTION il IMPORTANT SAFETY PRECAUTIONS continued Electric Shock ELECTRIC SHOCK can kill e Install and maintain equipment according to USA Standard C1 National Electric Code e Proper grounding procedures must be adhered to when using plasma arc cutting equipment The workpiece must be grounded to a solid electrical ground Do not contact electrically live parts Do not touch torch parts when input power is present in the power supply e Insulate yourself and others from the workpiece and ground Replace any cracked or damaged insulating parts including torches hoses and leads e Disconnect power source before disassembling the torch Turn off primary power before working on torch parts including changing cups and tips e The shield cup must be installed prior to operating the torch e When operating plasma arc cutting equipment in a damp or wet area extra care should be taken e Use this equipment for plasma cutting and gouging only It is not designed for any other cutting or welding process e Use only the torches specified in this instruction manual Fire FIREcan be caused by hot slag and sparks e Remove combustibles from working area or provide a fire watch e Do not cut containers that have held combustibles Remove all flammable and combustible materials in the operating ar
5. ss ssssssstssssrsttsrteeet e Figure 5 D 51 5 7 Rear Panel Components nen Figure 5 E 52 Parts listed without item numbers are not shown but may be ordered Order replacement parts by catalog number and complete description of the part or assembly as listed in the description column of the Parts List Also include the model and serial number of the unit Address all inquiries to your authorized Thermal Dynamics distributor If a Thermal Dynamics product must be returned for service contact your Thermal Arc distributor Materials returned to Thermal Dynam PARTS LISTS 5 2 SYSTEM COMPONENTS AND ACCESSORIES Item Qty Catalog Description No Number Complete systems include power supply with 230V primary power cable work lead PCH M 35 torch with leads and torch spare parts kit Machine torch systems include metal mounting tube and pinion assembly and remote pendant control with ON OFF switch 1 6249 Pak Master 50 with PCH 35 70 Torch and 12 5 ft 3 8 m Leads 1 6250 Pak Master 50 with PCH 35 70 Torch and 25 ft 7 6 m Leads 1 6251 Pak Master 50 with PCH 35 70 Torch and 50 ft 15 2 m Leads 1 6252 Pak Master 50 with PCH 35 90 Torch and 12 5 ft 3 8 m Leads 1 6253 Pak Master 50 with PCH 35 90 Torch and 25 ft 7 6 m Leads 1 6254 Pak Master 50 with PCH 35 90 Torch and 50 ft 15 2 m Leads 1 6255 Pak Master 50 with PCM 35 Machine Torch and 12 5 ft 3 8 m Leads 1 6256 Pak Master 50 with PCM 35 Ma
6. Pak Master 50 Lower Side Panel Overlay TDC Input Power Connection Label USA Label Warning Label Enclosure Half Input Power Cable Assembly 220V Middle Chassis Panel Resistor 50 ohm 50 watt Resistor 6k ohm 50 watt Resistor Mounting Clip Top Chassis Panel PC Board Support Ground Tag Input Filter Capacitors Kit is Two Complete Boards Input Rectifier Bridges Kit is Three Bridges with all hardware Overvoltage Protection Board 50 Manual 0 2444 5 6 CHASSIS COMPONENTS continued Wh Figure 5 D Chassis Components Manual 0 2444 51 PARTSLISTS 5 7 REAR PANEL COMPONENTS 8 4243 Ground Tag 9 6247 Adaptor Rear Panel Fitting 9 6235 Fan Heatsink Gasket 9 6250 Primary Block Cover 9 6251 Voltage Selection Panel Cover 9 3294 14 Pin Plug for J24 Item Qty Catalog Description No Number 1 1 9 6228 Rear Panel 2 1 9 6209 Fan Assembly 3 3 9 6229 Single Circuit Receptacle 4 1 9 6230 Fitting 1 4 NPT x 3 8 Tube 5 1 8 4289 Flex Connector 6 1 8 4251 Finger Guard 7 2 9 6231 Nine Circuit Receptacle 8 1 9 3861 Fuse 2 amp 600V 9 3 Retaining Ring 300 inch I D 10 1 9 2937 Fuse Holder 11 1 9 6232 Adaptor Inert B to 1 4 NPT Female 12 1 9 6233 Retaining Ring 75 inch I D 13 1 9 6234 Hole Plug 14 1 8 6214 Amber Lamp 1 1 1 1 1 1 5 gt dm dg c C LA Figure 5 E Rear Panel Components PARTS LISTS 52 Manual 0 2444
7. 1 Current set too low 2 Torch is being moved too fast across workpiece 3 Excessive oil or moisture in torch 1 Bad CSD relay on LDD board 1 K1 relay on Pilot board not working properly 27 REMEDY 1 Release switch and wait at least 20 seconds before activating switch again 2 Check DC output 1 Hold torch 1 8 3 8 inch 3 9 mm from workpiece 2 Make sure work lead is connected securely check continuity if necessary 3 Check D23 indicator on LDD board If not lit send unit to an authorized service center 1 Increase current setting 2 Reduce cutting speed 3 Hold torch 1 8 inch 3 mm from clean surface while purging and observe oil or moisture buildup do not activate torch 1 Try adjusting output using CSD pot through front panel 1 Check D9 on Pilot board If it is not on when cutting replace the Pilot board see page 44 SERVICE 4 3 ADVANCED TROUBLESHOOTING AND TESTING If the problem cannot be solved by the basic external trouble shooting guide the power supply enclosure will have to be removed If the technician does not have the proper training or equip ment to prcoeed with this Section send the unit to an authorized service center for repair Tools Required Digital Volt Ohmmeter Never open the power supply enclosure unless the primary input power to the system is disconnected from the source Opening the Enclosure To remove the enclosure 1 Remove the fi
8. ON position supplies AC power to activate all system control circuits OFF position deactivates control circuits RUN SET Switch RUN position is used for torch operation SET position is used for setting gas pressure and purging lines AC Indicator Green LED light indicates AC input power is present in the system when the ON OFF switch is in ON position TEMP Indicator Green LED light indicates proper operating temperature range Red light indicates overheating unit must be allowed to cool PIP Parts In Place Indicator Yellow LED light indicates proper torch assembly Light goes out if the shield cup is not fully seated against the PIP pins in the torch body GAS Indicator Yellow LED light with RUN SET switch in SET position indicates adequate gas pressure 42 psi or 2 9 BAR flowing to the torch Light goes out in RUN position until torch is activated DC Indicator Yellow LED light indicates adequate DC power output for main arc when the torch is activated PILOT Indicator Yellow LED light indicates pilot arc circuit is activated Light goes out when main arc is established and comes back on if the main arc is interrupted and pilot arc restarts Corner Slowdown Adjustment Sets corner slowdown CSD output to a percentage of main output Minimum output during CSD is 15 amps Turn fully clockwise for maximum output 100 of main current during CSD See Corner Slowdown
9. if not properly followed may cause damage to the equipment A WARNING A procedure which if not properly followed may cause injury to the operator or others in the operating area INTRODUCTION IMPORTANT SAFETY PRECAUTIONS Operation and maintenance of plasma arc equipment involves A WARNING potential hazards All operators and personnel should be alerted to possible hazards and precautions should be taken to prevent possible injury Gases and Fumes GASES AND FUMES produced during the plasma cutting process can be dangerous and hazardous to your health A e Ventilation must be adequate to remove gases and fumes during operation Threshold limit values and how to measure the amounts to assure adequate ventilation are found in publi cation A page iv e Vapors of chlorinated solvents can form the toxic gas phosgene when exposed to ultraviolet radiation from an electric arc Solvents degreasers and potential sources of these vapors must be removed from the cutting area Keep all fumes and gases from the breathing area e Use a downdraft cutting table or water table to capture fumes and gases e Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases Arc Rays ARC RAYS can injure eyes and burn skin e Use a welding shield with proper filter A 4 filter or darker is LI recommended for drag cutting A 10 filter or darker is recom mended when cutting with a standoff
10. terminals Manual 0 2444 4 3 ADVANCED TROUBLESHOOTING GUIDE continued SYMPTOM G Two seconds after activat ing torch DC indicator does not come on H After activating torch switch DC indicator comes on but no pilot arc Manual 0 2444 POSSIBLE CAUSE 1 Faulty LDD board 2 Faulty FET or pilot PC board 3 Faulty connections or wiring 1 No spark at spark gap faulty transformer T2 or LDD board 2 Faulty torch or torch parts 33 1 REMEDY Replace LDD board 2 Check for 300 VDC 10 between terminal El and E2 of capacitor PC board A Repeat for cap board B If 300 VDC is present FET or pilot PC board is faulty 3 If 300 VDC is not present m on either side check wiring and connections between input block and bridges BR1 BR3 on FET and pilot boards If no wiring problem is found or if voltages on cap boards A and B are unbalanced by more than 4 VDC or D51 is lit on the LDD board check the 6K pwr resistors near rear under heatsinks If OK replace LDD board Observe spark gap when activating torch If no spark is evident check for 120 VAC between J18 1 and J18 3 when the torch is activated If 120 VAC is present replace T2 If 120 VAC is not present replace LDD board DO NOT ATTEMPT TO MEASURE ANY VOLT AGES AT THE SPARK GAP ASSEMBLY 2 If spark is visible when torch is acticvated check torch parts or replace torch if necessary SERVICE 4 3 ADVA
11. B5 L3 INPUT X TERMINAL B1 J5 LOGIC PCB 48 PIN RIBBON B5 L4 PILOT INDUCTOR 6MHY E9 up POWER INPUT 4 PIN c2 L5 HF INDUCTOR BuHY ca 37 REMOTE CONTROL OPTION 9 PIN A3 L6 POWER INDUCTOR 15 UHY ce J8 FILTER PCB 4 PIN B8 11 L7 STEEL CORE INDUCTOR 6 MHY 08 19 NOT USED LB FERRITE FILTER C9 J1 FET PCB 1 PIN RIBBON c5 LTI 25 VAC AMBER NEON B2 J11 FET PCB 1 PIN RIBBON c5 WA 41 Ps1 PRESS SW 42 PSI 88 J12 FET PCB 20 PIN RIBBON cs BRI BRIDGE RECTIFIER 35A 608V CI J13 FET PCB 29 PIN RIBBON c5 L t BR2 BRIDGE RECTIFIER 35A 680V Ci J14 AUX TRANSFORMER PRIMARY B3 EN SOL SOLENOID 115VAC AB J15 AUX TRANSFORMER SECONDARY 84 T1 AUX TRANS 215 395 468 PRI B4 J16 NOT USED 58 12 V amp 36V CT SEC J17 NOT USED x Say T2 HF TRANS 115V PRI 6KV SEC ca J18 HF TRANSFORMER ca oo c T3 SMPS TRANSFORMER CB J19 NOT USED J28 PILOT PCB 18 PIN RIBBON E6 R1 2 RESISTOR 6K OHM 5 WATT C3 03 J21 PILOT PCB 34 PIN RIBBON E7 R3 4 RESISTOR 58 OHM 5 WATT E5 J22 NOT USED 36 R5 RESISTOR 1 K OHM 1 WATT 82 J323 NOT USED nB RESISTOR 1 OHM 12 WATT D8 J24 REAR PANEL REMOTE 16 PIN A R7 VARISTOR 558 VAC 22BJOULES C2 J25 TORCH QUICK CONNECT 14 PIN Dia A 00804 1 2 3 4 5 APPENDIX 54 Manual 0 2444
12. Installing Refer to Figure 2 F and pie Fer 1 Press fit the nylon screw receptacles into the rear panel openings as shown 2 Secure the air filter with bracket to the power supply with the 1 2 in pan head screws 3 Connect the 1 4 NPT male coupling of the gas hose assembly to the power supply first then connect the female JIC fitting to the air filter Tighten both fittings with a 9 16 in wrench NOTE Supply hoses must be at least 6 hose 3 8 in or 9 5 mm I D Nylon Screw Receptacles Air Filter Assembly _ MM eo_ e m 1 4 NPT Rear Panel Fitting E 1 4 NPT Figure 2 F Gas Connections Using Optional Air Line Filter Manual 0 2444 13 INSTALLATION INSTALLATION 14 Manual 0 2444 SECTION 3 OPERATION 3 1 OPERATING CONTROLS PIP Parts In Place Indicator GAS Indicator TEMP Indicator DC Indicator AC Indicator PILOT Indicator RUN SET Switch CSD Control ON OFF Switch Current Control E aoe wy csr L GAS DC PILOT CURRENT BAND PLASMA CUTTING SYSTEM L Gas Pressure Gauge TORCH Receptacle GAS PRESSURE WORK Cable Gas Pressure Control d A 00772 Figure 3 A Operating Controls See Table 3 A page 16 Manual 0 2444 15 OPERATION INDICATOR ON OFF Switch 3 1 OPERATING CONTROLS continued FUNCTION
13. fu lw j EH E42 E26 E27 E33 J20 DO DO 07 BE D_ D o o E34 B A IPH ki SHUNT U 9 9925 OHMS E28 A K mi A je E29 GNO E E35 pane Ss OUTPUT IB 7 L UT I PILOT PCB E It 30 59 E16 mr Isi y ke 420789 SCHEMATIC ss Ka 19X1065 ASSEMBLY Gan Ki 4 E16 114x149 PCB IPH I A 68 T ep L4 E16 Re el E REV REVISION DATE E43 Ke A INITIAL EC6904 2 29 E38 d E39 wm Ka As E40 E41 E17 E44 PAK MASTER SYSTEM BLOCK DIAGRAM DATE 981711795 E 9 420878 0870 S1A 6 7 8 9 10 A 00804 Manual 0 2444 55 APPENDIX APPENDIX 56 Manual 0 2444
14. of burning or arcing anywhere in the unit When disconnecting or connecting any of the connectors from the board support the board under the connector to keep from putting too much stress on the board To replace the LDD board assembly 1 Disconnect Jl J2 J4 J5 and J16 if present from the LDD board gently folding back the harness and ribbon cables out of the way New LDD boards have no J16 The J16 cable should be removed from the unit when updating to a new LDD board 2 Remove the mounting screw near the middle of the board 3 With a small screwdriver loosen the locking screw in the current adjust knob and remove the knob 4 Gently squeeze the top of the two rear plastic mounting standoffs to release the board Lift the rear end of the board just enough to clear the locking tabs 5 Squeeze the tops of the two front standoffs and lift the board enough to clear the locking tabs By lifting the rear of the board gently remove it taking care not to get it caught on the front panel holes for the switches or current control pot 6 Install new board by tipping the front end of the board down and putting the switches LED and current control pot 42 Manual 0 2444 4 4 SERVICE PROCEDURES continued Manual 0 2444 Fan Assembly through the front panel openings and moving the board until the two front mounting holes are over the standoffs 7 Lower the board onto the four standoffs and screw in the board mounting
15. replacement inductor do not force it into place Work Lead Inductor L7 The work lead inductor has a core of steel laminations and should never need replacing If any burning or arcing is visible on the work lead inductor return the unit to an authorized service center Main Output Inductor The only reason the main output inductor should be replaced is if L6 the cores are cracked due to shipping damage or the unit being dropped Minor chips are normal If any burning or arcing is visible on the output inductor return the unit to an authorized service center To remove the main output choke 1 Remove the hardware which connects the lead wire on one terminal and the copper link on the other terminal 2 Turn the unit on its side and remove the two mounting nuts and lockwashers which secure the main output choke to the bottom chassis Remove the component from the unit 3 Install the replacement main output choke by reattaching the mounting and terminal hardware SERVICE 40 Manual 0 2444 4 4 SERVICE PROCEDURES continued Auxiliary Transformer T1 High Frequency Transformer T2 Spark Gap Assembly HF Inductor L5 Manual 0 2444 To replace the auxiliary transformer 1 Disconnect the single pin connector on the white wire coming from the auxiliary transformer 2 Using a pin removal tool remove the pins from connectors J14 A J14 B and J14 C on the voltage selection panel 3 Disconne
16. to the ground stud Do not ground the remote control wire harness to the system ground stud which is visible on the top panel of the power supply 6 Using the four 6 32 screws with locknuts install the remote control receptacle J24 in the rear panel position the recep tacle in the hole from INSIDE the unit 7 Before reassembling the power supply enclosure check that all wire harnesses and ribbon cables are properly located in the notches of the top and middle panels 8 Position the unit in an upright position Tip the unit and slide one of the case halves onto the chassis Then lift the unit and set it down on its side with the case half down 9 Before installing the other case half make sure the edges of the bottom middle and top chassis panels are fully inserted into the slots in the case Look for gaps between the front and rear panels and the edge of the case Look into the case to see that the notches in the top corners of the front and rear panels are flush against the plastic stops of the case Some lifting and re settling of the chassis may be required to get all compo nents aligned correctly 10 Gently lower the other half of the enclosure onto the other side of the chassis by tipping it slightly so that the top is slightly lower than the bottom Then push and gently tap down until the two case halves are within 1 16 inch If you have trouble getting the case halves close enough remove the top half and che
17. 1 06 in 27 mm 78 mm 8 95 in L 227 mm 6 21 in 158 mm Min 14 72 in 374 mm Max 1 38 in 1 06 in 35 mm 0 20 in 5 mm 27 mm Y 5 zo i 16 60 in 422 mm gt A 00009 Figure 1 B PCH M 35 Torch Dimensions Manual 0 2444 3 GENERAL INFORMATION 1 3 OPTIONS AND ACCESSORIES Pak Master 50 System Options and Accessories Torch Options and Accessories GENERAL INFORMATION NOTE s Remote Control RC Wire Harness Cat No 9 6210 For converting a hand cutting system to mechanized use with a remote hand pendant control or computer control CNC cable Remote Hand Pendant Control Cat No 7 3114 Hand held remote ON OFF control device for systems with remote wire harness installed Includes a 25 ft 7 6 m cable Computer CNC Interface Cable 25 ft 7 6 m Cat No 8 5557 Computer CNC Interface Cable 50 ft 15 2 m Cat No 8 5558 For interfacing the power supply with a computer or auxiliary control device Provides ON OFF OK to move and corner slowdown signals Remote wire harness must be installed e High Pressure Regulator Air Cat No 9 3022 High Pressure Regulator Nitrogen N2 Cat No 9 2722 s Running Keane Cat No 7 3201 For transporting the system with torch and leads storage Air Line Filter Single Stage nn Cat No 7 3265 Air Line Filter Two Stage nenn Cat No 7 3340 Remove damaging moisture and conta
18. 6 inch 3 5 mm 3 Install a 10 ring terminal on the ground GND wire of the input power cable end of the cable Electric shock and damage to the unit could occur if power is applied to the GND terminal Make sure the ground wire is designated as GND on the other A WARNING 4 Connect the input power cable according to Figure 2 F Terminal L3 is not used for single phase connections INSTALLATION 8 Manual 0 2444 2 2 ELECTRICAL CONNECTIONS continued Ground Wire 230V Input Cable Factory Installed Input Power Cable e Input Power Cable Connections Single Phase 18 Three Phase 39 le GND LI GND S gt Access Cover L2 LO ae EE A 00755 Figure 2 C Input Power Cable Connections Input Current Recommended Sizes 1 Ph 3 Ph Fuse Amps Wire AWG Wire Canada Amps Amps 1 Ph 3 Ph 1 Ph 3 Ph 1 Ph 3 Ph Table 2 A Line Voltages with Recommended Circuit Protection and Wire Sizes Based on Table 310 16 1987 National Electric Code and Table 4 Canadian Electrical Code Manual 0 2444 9 INSTALLATION 2 3 WORK CABLE AND GROUND CONNECTIONS Electromagnetic Interference EMI Creating an Earth Ground Work Cable Connection Figure 2 D Work Cable Connection INSTALLATION High frequency pilot arc initiation generates electromagnetic interference EMI commonly called RF noise EMI m
19. A WARNING Basic and Advanced Two levels of troubleshooting are covered in the troubleshooting Troubleshooting guide The first basic level of troubleshooting are those which can be performed without special equipment or knowledge and without removing the plastic enclosure from the unit The second advanced level of troubleshooting provides procedures for replacing components and subassemblies which will allow the technician with a few common tools to remove the plastic enclosure and analyze some failures NOTE Advanced troubleshooting steps are marked with an asterisk If major complex subassemblies are faulty the unit must be returned to an authorized service center for repair SERVICE 24 Manual 0 2444 4 2 POWER SUPPLY TROUBLESHOOTING continued SYMPTOM A AC indicator not lit B AC indicator lit TEMP indicator red C AC indicator lit TEMP indicator green PIP indicator not lit Manual 0 2444 POSSIBLE CAUSE 1 Input power not properly connected to input panel 2 Input power selection does not correspond to actual input voltage 3 Input fuse blown 4 Faulty LDD PC board 1 Unit is overheated 2 Fan not running or airflow obstructed 3 Faulty LDD board 1 Torch not properly con nected to power supply 2 Shield cup not properly installed on torch 3 Faulty PIP assembly in torch holder 4 Faulty pins inside torch quick disconnect 25 REMEDY 1 Check t
20. EL gt J14 Jiac AEN EN 15 FINN 2 AMP BL ITS 3 a 36VAC CT Sie CONNECT J14 TO 3148 f Rosis 5 WD J14A 11 VAC HOT NW E J14A FOR 208 240V E EMI KEE J148 FOR 380 415V L 156 18 sd J14C FOR 462V 11 VAC Li gq tL BLACK H AUX XFMR RETURN B INPUT 2 WHITE 2 2 200 460 VAC I P 128 3 PHASE La o2 PED GRN YEL GND G ec J4 39 1 CURRENT 1 1 SENSE 62 19 PIN 2 RIBBON CONNECTOR J68 FOR 62 2 d TE 380V 46aV z z D ca H ao am 14 CAP PCB mp mp 420791 SCHEMATIC 1 1 19X841 ASSEMBLY Els E13 D I J11 114X151 PCB BR3 BR1 BR2 R7 40 E3 E1 Ach E AC AC AC AC AC AC EIA Et Y PILOT Y FET Y PILOT E5 140 EIA EN Heatsink Heatsink Heatsink R2 BK LL 13 saw A A 34 E4 gt EZ EL J6A 1 68 E2A E2 000000000 000000000 gt E2A 1234567839 1234567839 el E5 dE2A PLUG J6 INTO J6A FOR 38 V 46 V 41 E3 E1 E3 PI T FOR 24 LUG J6 INTO J6B FOR 220V 240V SCH EIR amp E5 41 rfa 17 2 3 4 06 267 ECH WE Rt A D A 2 A bE A Saw B 34 J B am 13 E4 e7 36 13 gt 13 13 E2 E4 E2A E2 E4A amp 36 ES E2A B CAP PCB 42C791 SCHEMATIC 19x841 ASSEMBLY 114x151 PCB 11 4 11 48 36 48 _ R3 36 sa L DESIG DISCRIPTION ZONE DESIG DISCRIPTION ZONE in 5aw 1FU 2 AMP 688 VOLT B2 J1 LOGIC PCB 24 PIN A4 Mi FAN 115VAC Ag 32 LOGIC PCB 34 PIN RIBBON 87 Li INPUT 2 TERMINAL B1 33 NOT USED L2 INPUT g TERMINAL Bt J4 LOGIC PCB 29 PIN RIBBON
21. ERAL INFORMATION nennen nennen 1 1 SYSTEM DESCRIPTION eee 1 2 SPECIFICATIONS vi ainiin 2 died avis 1 3 OPTIONS AND ACCESSORIES sse eee eee SECTION 2 INSTALLATION see 2 1 REMOTE CONTROL HARNESS INSTALLATION sese ee 2 2 ELECTRICAL CONNECTIONS 0 eee eects eeeeeeeneeeeeenaaes 2 3 WORK CABLE AND GROUND CONNECTIONS sece 2 4 GAS CONNECTIONS AAA SECTION 3 OPERATION TTT 3 1 OPERATING CONTROLS nennen 3 2 GETTING STARTED pA ecean ie tane aee anh fl fr duets 3 3 SEQUENCE OF OPERATION 3 4 OPERATING THE SYSTEM 3 5 RECOMMENDED CUTTING SPEEDS ecen SECTION 4 CUSTOMER OPERATOR SERVICE A 4 1 GENERAL POWER SUPPLY MAINTENANCE scce 4 2 POWER SUPPLY TROUBLESHOOTING sser 4 3 ADVANCED TROUBLESHOOTING AND TESTING 4 4 SERVIGE PROGEDURES a doeisentatanes teense aiti SECTION 5 PARTS LISTS inserer 5 1 ORDERING INFORMATION A 5 2 SYSTEM COMPONENTS AND ACCESSORIES see 5 3 FRONT PANEL COMPONENTS A 5 4 REGULATOR SOLENOID ASSEMBLY oseere 5 5 BASE PANEL COMPONENTS AAA 5 6 CHASSIS COMPONENTS AAA 5 7 REAR PANEL COMPONENTS AAA APPENDIX I SYSTEM SCHEMATIC iii INTRODUCTION NOTES CAUTIONS AND WARNINGS Throughout this manual notes cautions and warnings are used to highlight important information These highlights are catego rized as follows NOTE Anoperation procedure or background information which requires additional emphasis or is helpful in efficient operation of the system Ms CAUTION A procedure which
22. Faulty LDD board 3 Faulty solenoid 1 Switch activated during 20 second pre flow 2 Faulty torch parts 3 Gas pressure too high 4 Faulty high frequency trigger circuit 26 REMEDY 5 Check and replace if necessary See Service Procedures page 42 1 Check source for at least 70 psi 4 8 BAR In SET position adjust gas pres sure to 70 psi 2 Check and replace if necessary See Service Procedures page 42 3 Check and replace if necessary See Service Procedures page 42 4 Check and replace if necessary See Service Procedures page 42 1 Set switch to RUN position 2 Check and replace if necessary See Service Procedures page 42 3 Check and replace if necessary See Service Procedures page 42 1 Release switch and wait at least 20 seconds before activating switch again 2 Inspect torch parts and replace if necessary 3 Set pressure to 70 psi 4 8 BAR 4 Check spark gap assembly Manual 0 2444 4 2 POWER SUPPLY TROUBLESHOOTING continued SYMPTOM G DC indicator not lit when torch switch is activated H Torch pilots but does not cut I Torch cuts but not ad equately J No Current control using front panel pot K Poor tip life Manual 0 2444 POSSIBLE CAUSE 1 Switch activated during 20 second pre flow 2 DC output not present 1 Torch too far from workpiece 2 Work lead not connected 3 Power supply not sensing transfer current
23. IHERMAL DYNAMICS A THERMADYNE Company PAK MASTER 50 Air Plasma Cutting System Service Manual March 13 1998 Manual No 0 2444 A WARNING A WARNING Read and understand this entire Service Manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this manual represents our best judgement Thermal Dynamics Corporation assumes no liability for its use Pak Master 50 Air Plasma Cutting System Service Manual Number 0 2444 Published by Thermal Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1995 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 Pak Master 50 Air Plasma Cutting System Service Manual whether such error results from negligence accident or any other cause Printed in the United States of America March 13 1998 RECORD SERIAL NUMBERS FOR WARRANTY PURPOSES Purchase Date Power Supply Torch TABLE OF CONTENTS INTRODUCTION T NOTES CAUTIONS AND WARNINGS serres IMPORTANT SAFETY PRECAUTIONS serre PR CAUTIONS a An nun STATEMENT OF WARRANTY SECTION 1 GEN
24. ISSEMENT A La mise en oeuvre et l entretien de tout quipement plasma implique des dangers potentiels Le personnel doit etre mis en garde contre les risques suivants et toutes les pr cautions doivent etre prises pour eviter de prendre des risques pour la sant Les gaz et les fumees A LES GAZ ET LES FUMEES peuvent etre dangereux et constituer un risque pour votre sante e La ventilation doit tre suffisante pour vacuer les fum es lors de la coupe Dans la publication A page vii vous trouverez la facon de mesurer les quantit s permettant d affirmer que la ventilation est ad quate ainsi que les valeurs limites ne pas d passer e Les vapeurs de solvants chlor s peuvent former un gaz toxique le Phosg ne lorsqu elles sont expos es aux radiations ultravi olettes mises par l arc lectrique Tous les solvants d graissants et sources potentielles de ces vapeurs doivent tre enlev s de l aire de coupe e Evacuer toutes les fum es et les gaz de l aire de respiration e Utiliser un tabli de coupe tirage vers le bas pour attirer les fum es et les gaz e Utiliser un masque aves arriv e d air si la ventilation n est pas suffisante pour liminer tous les gaz et fum es V INTRODUCTION PRECAUTIONS continuer Les rayons de l arc Decharge electrique Un encendie INTRODUCTION LES RAYONS DE L ARC peuvent abimer les yeux et bruler la peau e Utiliser un cran de sou
25. L4 Work Lead Inductor L7 Main Output Choke L6 Auxiliary Transformer T1 High Frequency Transformer T2 Spark Gap Assembly Air Core Inductor L5 Solenoid Regulator Gauge Assembly LDD PC Board Assembly Fan Assembly If the visual inspection shows any parts that are burned or scorched it is an indication that something has gone wrong in the major power processing portions of the unit Do not attempt to repair the burned portion and re apply power or more serious damage to the unit may occur Instead return the unit to an authorized service repair center The following tests should be performed with no input power connected to the unit Remove one wire from power resistor R1 and one from R2 These are located on the underside of the middle panel adjacent to the FET board assembly With a digital volt ohmmeter DVM measure the resistance of each of these resistors Each should measure 6k ohms 5 Then measure the resistance of each cap bank A and B This is done by connecting the positive lead of the meter to terminal E1 or E1A of cap bank A and the negative lead of the meter to terminal E2 or E2A As the cap bank charges the meter reading should increase to greater than 100k ohms Repeat for the B cap bank If these meter readings are not greater than 100k ohms there is a problem with the major power processing circuits in the unit and it should be returned to an authorized service center If readings are gr
26. Manual 0 2444 53 APPENDIX APPENDIX I SYSTEM SCHEMATIC 3 REMOTE CONTROL OPTION VOLTAGES NOMINAL ZONE J15 1 TO J15 3 18VAC 84 REAR PANEL J15 3 TO J15 5 18VAC 84 J15 2 TO J15 6 11 VAC B4 126 17 A CAP Ef TO E2 388VDC C3 ts 5 171 Dr TO MOVE 7 kia Dr Ar B CAP Ef TO E2 3 Vv0C 03 4 5 ER OK TO MOVE RTN 8 14 ok ro A 13 MOVE DC OUTOUT E42 TO E26 3 1 9 START STOP REM 9 21 NE RER rotot ea d E EE START STOP REM RTN 4 22 ee CUTTING 11 VDC E8 18 3 15 EE Le 5 15 J common An 4 5 CORNER SLOW DOWN AIN 6 16 x SAFE TO CHECK E42 TO E26 W METER DO NOT CHECK E42 TO E3 HF PRESENT zj VOLTAGE 1 NOTES SUPPRESSION J 1 FOR 1 CONNECT LINE TO L1 AND L2 Fr ASSY TAKIARA a 14 2 FOR 3 PLUGS X BLACK 1 tFU 18 RD JIS 1 t 5 Y WHITE Z RED GNO GRN Y
27. NCED TROUBLESHOOTING GUIDE continued SYMPTOM POSSIBLE CAUSE REMEDY I Intermittent pilot arc 1 Worn torch parts 1 Check and replace torch parts if necessary 2 Low input voltage 2 Measure actual input voltage Low input voltage levels may cause sputter ing pilot but should not affect main arc transfer and cutting operation if within recommended voltages ranges SERVICE 34 Manual 0 2444 4 4 SERVICE PROCEDURES This section explains how to remove and replace any of the replaceable subassemblies listed in the Troubleshooting Guide the torch leads or power supply A WARNING Disconnect primary power to the system before disassembling Opening the Enclosure There are eight mounting screws with nuts which secure the enclosure Lay the power supply on its side with the mounting screw heads facing up Remove the mounting screws and care fully lift the upper enclosure half from the chassis Power Component If a main power supply failure is suspected it is important to test Service the input bridge rectifiers main filter capacitors and main FET switching assembly Typically a failure of one of these compo nents will result in the failure of one of the other The first three procedures in this section are meant to be done as a group Manual 0 2444 35 SERVICE 4 4 SERVICE PROCEDURES continued Input Bridge If the mains circuit breaker has tripped or fuses blown the input Rectifiers bridge r
28. Operation page 29 Current Control Selects output current Pressure Gauge Displays input pressure to the torch Pressure Control OPERATION Adjusts pressure from the regulator Pull knob out and turn clockwise to increase pressure to desired level Table 3 A Operating Controls 16 Manual 0 2444 3 2 GETTING STARTED A WARNING Disconnect primary power at the source before disassembling the power supply torch or torch leads Check Torch Parts Check Input Power Connect Work Cable Check Gas Supply Purge the System Gas Pre Flow Select Output Current Set Operating Pressure Manual 0 2444 Follow this set up procedure each time the system is operated 1 Check the torch for proper assembly and appropriate front end torch parts see Operators Manual 0 2344 2 Check primary power source as follows a Check the power source for proper input voltage Make sure the power source meets circuit protection and wiring requirements see Table 2 A page 9 b Make sure that the power supply is set for the proper voltage see Electrical Connections page 7 c Connect the input power cable or close the main discon nect switch to supply power to the system 3 Check for a solid work cable connection to the workpiece 4 Select desired gas air or nitrogen Make sure gas sources meet pressure and flow requirements see Gas Connections page 11 Check connections and turn ga
29. There should be no strain on the rectifier terminals One AC input wire is longer than the other wire accordingly 3 Use a new insulator pad between the heatsink and bridge rectifier Be sure both surfaces are clean and smooth before mounting replacement rectifier 4 Use a star washer between the screw head and the rectifier Cover the screw head with RTV silicon caulk to prevent electrical arcing Two input filter capacitor boards are mounted to the main FET heatsink assembly Both capacitor boards must be replaced if one is found to have failed or is suspect Proper measurement of the capacitor boards requires the use of a capacitance meter If the capacitor boards can not be tested and the input rectifiers or main FET assembly are failed replace the capacitor boards as well Be sure that the voltage selection plug is set for HIGH 380 460v 1 Each capacitor board should measure 1 100uf between El and E2 2 D1 D2 and D3 on each capacitor board must also be tested Scrape away a small amount of conformal coat from the diode leads to make these measurements With the digital voltmeter set to the diode drop range D1 and D2 should read 1 0v D3 should read U Y Keen lt gt mL D2 1 LDS Capacitor Board Detail Note Orientaion of D1 D2 and D3 Cap Boards Figure 4 B Input Capacitor Location 37 SERVICE 4 4 SERVICE PROCEDURES continued Main FET If the input bridge re
30. Washer 6 2 Socket Retaining Ring Clip 7 1 9 6237 RF Filter PC Board Assembly PCB 8 1 9 6221 Socket Assembly Plasma 9 1 8 6332 Socket Assembly Secondary 10 2 8 7071 Hole Plug 1 4 11 2 9 6240 Bumper Locking Tab Signal Connector 12 1 8 4249 Strain Relief Work Cable 13 1 8 4247 Work Cable with Clamp 10 ft 1 8 5560 Work Cable Clamp 1 8 4243 Ground Tag Not Shown A 00763 Figure 5 A Front Panel Components Manual 0 2444 47 PARTS LISTS 5 4 REGULATOR SOLENOID ASSEMBLY Item Qty Catalog Description Reference No Number Designator 1 9 6207 Regulator Solenoid Assembly Includes 1 1 8 4382 Regulator 2 1 8 3370 Solenoid Valve 1 8 NPT SOL 3 1 8 5533 Pressure Switch 42 psi PS 4 1 8 0354 Fitting 1 8 NPT Close Nipple 5 1 8 3369 Street Elbow 1 4 NPT Female to 1 8 NPT Male 6 1 9 6220 Gauge 0 100 PSI BAR 7 1 9 6230 Fitting 1 4 NPT x 3 8 Tube Straight 8 1 9 2023 Fitting 1 4 1 8 NPT Reducer 9 1 9 6219 Fitting 1 4 NPT x 3 8 Tube 90 Degree 6 A 00764 5 Figure 5 B Regulator Solenoid Assembly PARTS LISTS 48 Manual 0 2444 5 5 BASE PANEL COMPONENTS Item Qty Catalog Description Reference No Number Designator 1 1 8 2192 Auxiliary Transformer T1 2 1 9 6202 Work Lead Inductor L7 3 1 9 6203 Inductor Assembly L6 4 1 9 5528 High Frequency Transformer Assembly T2 5 1 9 6205 Spark Gap Assembly 6 1 9 6229 Single Circuit Receptacle 7 1 9 6200 Main Transformer T3 8 1 9 6201 Pilot Indu
31. ay interfere with nearby electronic equipment such as CNC controllers etc Torch leads are shielded to help prevent this problem To further minimize RF interference follow these grounding procedures when installing mechanized systems 1 Install a ground wire not included between the internal ground stud in the power supply and a solid earth ground or star ground To create a solid earth ground drive a 1 2 in 12 mm copper rod approximately 6 8 ft 1 8 2 4 m into the earth so that the rod contacts moist soil over most of its length The depth required will vary depending on location Locate the rod as close as possible to the power supply The work table should be connected to the same earth ground 2 Connect the control device CNC to a separate earth ground The ground cable should be at least 12 gauge wire 3 To minimize RF interference position torch leads as far as possible at least 1 ft or 0 3 m from any CNC components control cables or primary power lines 4 Keep torch leads clean Dirt and metal particles bleed off energy which causes difficult starting and increased chance of RF interference Refer to Figure 2 D and 5 Make sure the work cable is properly connected to the workpiece before operating the system Ve JBA Make a solid work cable connection to the work piece or cutting table A 00757 10 Manual 0 2444 2 4 GAS CONNECTIONS Gases Pressure F
32. chine Torch and 25 ft 7 6 m Leads 1 6257 Pak Master 50 with PCM 35 Machine Torch and 50 ft 15 2 m Leads 1 bek Mar Mar Mo Complete 575V Systems Only Complete 575V systems include power supply with work lead 575 VAC transformer assembly PCH M 35 torch with leads and torch spare parts kit Machine torch systems include metal mounting tube and pinion assembly and remote pendant control with ON OFF switch 1 6260 Pak Master 50 575V with PCH 35 70 Torch and 12 5 ft Leads 1 6261 Pak Master 50 575V with PCH 35 70 Torch and 25 ft Leads 1 6262 Pak Master 50 575V with PCH 35 70 Torch and 50 ft Leads 1 6263 Pak Master 50 575V with PCH 35 90 Torch and 12 5 ft Leads 1 6264 Pak Master 50 575V with PCH 35 90 Torch and 25 ft Leads 1 6265 Pak Master 50 575V with PCH 35 90 Torch and 50 ft Leads 1 6266 Pak Master 50 575V with PCM 35 Machine Torch and 12 5 ft Leads 1 6267 Pak Master 50 575V with PCM 35 Machine Torch and 25 ft Leads 1 6268 Pak Master 50 575V with PCM 35 Machine Torch and 50 ft Leads 1 m E FA a Koch bech i Mo PARTSLISTS 46 Manual 0 2444 5 3 FRONT PANEL COMPONENTS Item Qty Catalog Description Reference No Number Designator 1 1 9 6236 Front Panel 2 1 9 6207 Regulator Solenoid Assembly Refer to Section 5 4 for parts 1 9 5834 Quick Disconnect Replacement Kit Includes Items 3 6 3 1 Quick Disconnect Body 4 1 Quick Disconnect Retaining Ring Clip 5 1 Quick Disconnect Body Wave Spring
33. ck to see that the bottom half is fully engaged and that there are no wires out of place on the top and middle panels 11 Install the eight screws lockwashers and nuts to complete the assembly 6 Manual 0 2444 2 2 ELECTRICAL CONNECTIONS Primary Input Voltages ee CAUTION A WARNING The unit can accept any input voltage from 200V to 460V 10 single or three phase 50 or 60 Hz 575V input requires an addi tional step down transformer Catalog No 9 6211 Input voltage settings must be verified before applying power to the unit Refer to Figure 2 B below Disconnect primary power at the source before disassembling the power supply torch or torch leads Input Voltage Changeover Access Panel Manual 0 2444 1 Remove the voltage selection access panel 2 Connect the 9 circuit plug on the rear panel to the receptacle which corresponds with the actual primary input voltage HIGH for 380 415 460V or LOW for 200 220V 3 Connect the single circuit plug on the rear panel to the receptacle which corresponds to the actual primary input voltage 460V 380 415V or 200 220V 4 Replace the voltage selection access panel 200 22 380 415 460 IO VAC Detail of Voltage Connection Panel Access Panel Sc
34. ct the secondary wires by unplugging the J15 connector from the auxiliary transformer 4 Removing the four mounting screws and washers and re move the auxiliary transformer from the unit 5 Install the replacement transformer on the bottom chassis panel Reattach the J15 connector Connect the brown wire to the top connector on the voltage selection panel connect the orange wire to the middle connector and connect the black wire to the lower connector Connect the white wire to the free hanging single pin connector To replace the high frequency transformer 1 Disconnect the two high voltage leads from the spark gap assembly 2 Unplug the J18 connector 3 Remove the four mounting screws 4 Install the replacement HF transformer on the bottom chassis Plug in the J18 connector and replace the high voltage leads to the spark gap assembly To replace the spark gap assembly 1 Disconnect wires and remove the two mounting screws Remove the spark gap assembly from the unit 2 Install the replacement spark gap assembly 3 Connect the wiring 4 With a feeler gauge check the gap between the two elec trodes The gap should be 035 inches Adjust if necessary and tighten set screws There should be no reason to replace the HF inductor unless it somehow gets bent so it interferes with other components or the chassis To replace the HF inductor 1 Disconnect the HF inductor from the spark gap assembly and the torch con
35. ctifiers or capacitor boards are found to be Heatsink Assembly faulty the main FET heatsink assembly must be checked as well Refer to Figure 4 C and locate the main FET heatsink assembly on the right hand side of the unit Set the digital volt meter to the diode voltage drop range Make the following measurements to each capacitor board Terminal Reading E8 to E1A cap Bd B Av E9 to E2A cap Bd B Av E10 to E1 cap Bd A Av E11 to E2 cap Bd A Av Main FET Heatsink Assembly E1 ES En D E11 E2 Cap Board A Cap Board B Figure 4 C Main FET Heatsink Assembly NOTE Replacement main FET heatsink assemblies come complete with both input capacitor boards and input bridge rectifier When replacing the FET heatsink assembly keep the ribbon cables and wires recessed in the panels to avoid pinching in the case SERVICE 38 Manual 0 2444 4 4 SERVICE PROCEDURES continued Main Transformer T3 The only reason the main transformer should be replaced is if the cores are cracked due to shipping damage or the unit being dropped Minor chips are normal If any burning or arcing is visible on the main transformer return the unit to an authorized service center To remove the transformer 1 Remove the four mounting nuts on the FET board and the four mounting nuts on the pilot board which fasten the Blk and Wht wire or flat copper transformer leads to the PC boards 2 Remove curr
36. ctor Assembly L4 9 1 9 6213 Base Panel 10 2 9 3133 Fiber Washer 11 1 9 6214 Resistor 10 ohm 12 watt R 12 1 8 4281 Male Adaptor 13 1 9 5770 Disc Capacitor C 14 1 9 6239 Bracket Inductor Lead Connection 15 1 9 6203 HF Inductor Coil 1 8 4243 Ground Tag Not Shown Manual 0 2444 Figure 5 C Base Panel Components 49 A 00765 PARTS LISTS 5 6 CHASSIS COMPONENTS Item Qty Catalog Description No Number 1 1 9 6241 2 1 9 6242 3 1 9 6217 4 1 9 6243 5 4 8 0381 6 1 9 4146 7 1 9 6215 8 1 9 6244 9 1 9 6245 10 1 9 6208 11 1 9 6248 12 1 9 6249 13 1 9 6250 14 1 9 6251 15 1 9 6252 16 1 9 6253 17 2 9 6254 18 2 9 6255 19 1 9 6256 20 1 8 3216 21 1 8 6244 22 2 9 6257 23 1 8 4384 24 1 9 6224 25 2 9 6225 26 2 9 6226 27 8 9 6227 28 1 9 6222 29 4 9 6223 30 1 8 4243 31 1 9 6281 32 1 9 6273 33 1 9 6276 PARTS LISTS Input Voltage Connection Panel Terminal Block Pilot PC Board Heatsink Assembly Insulator Input Voltage Block Rubber Feet Current Control Knob FET PC Board Heatsink Assembly Tested with Cap Bds Rectifier Dust Shield Pilot PC Board Dust Shield FET PC Board LDD Log Gate Drive Display PC Board Assembly Ribbon Cable Assembly 34 Circuit Ribbon Cable Assembly Dual 10 20 Circuit Access Panel Input Voltage Connection Access Panel Voltage Changeover Vinyl Cap Torch Quick Disconnect Voltage Tag Upper Side Panel Overlay
37. d SYMPTOM D AC indicator on TEMP indicator green PIP indicator on GAS indica tor not lit E Fan does not turn POSSIBLE CAUSE 1 Insufficient gas pressure 2 Faulty pressure switch 3 Faulty LDD board 1 Air flow obstructed 2 Faulty fan REMEDY 1 Check gas connections Set regulator to at least 50 psi 2 Check for 0 VDC between terminals J1 11 and J1 12 If voltage is greater than 1 VDC replace solenoid regulator gauge assembly 3 If voltage between termi nals J1 11 and J1 12 is less than 1 VDC replace LDD board 1 Check for obstructions 2 Remove input power from unit Remove terminals from fan and check for 120 VAC on terminals with input power reapplied If 120 VAC is present replace fan Apply input power to the unit If the AC TEMP green PIP and GAS indicators are all lit then proceed The GAS indicator should go out when the 20 second gas pre flow is complete SYMPTOM F GAS indicator does not go out after 20 second pre flow SERVICE POSSIBLE CAUSE 1 RUN SET switch in SET position 2 Gas solenoid stuck open 3 Faulty LDD board or wiring 32 REMEDY 1 Make sure RUN SET switch is in RUN position 2 Replace solenoid or clean if gas flows with power on off switch off 3 Check for 15 VDC on gas switch terminals see Figure 6 D If 15 VDC is present replace LDD board see Section 6 4 If no 15 VDC check LDD wires and connection
38. dage muni d un filtre num ro 4 ou plus sombre en coupant au contact ou num ro 10 ou plus sombre en coupant distance e Porter des v tements protecteurs ad quats e Assurez vous que les autres personnes ne soient pas atteintes par les rayons Une DECHARGE ELECTRIQUE peut tuer e Faire l installation et l entretien de l appariel selon les normes du Code Electrique des Etats Unis Norme NEC USA Standard C1 ou celles en vigueur dans votre pays s Il faut appliquer les proc dures de mise la terre sp cifiques l utilisation de dispositifs de coupe au plasma La pi ce ou le m tal sur lequel une personne coupe doit tre reli e une bonne prise de terre e Ne pas toucher des pi ces sous tension e Isolez vous du courant de coupe et de la terre e Remplacer toute pi ce isolante fendue ou endommag e y compris le corps de torche et les c bles e Couper l alimentation avant la depose du chalumeau Couper l alimentation avant d intervenir sur la torche y compris pour changer la buse ou l lectrode e Avant d utilisere le chalumeau s assurer que l ecran de protec tion est en place e Soyez particuli rement vigilant lorsque vous coupez avec un appariel de coupe au plasma dans un endroit humide Les etincelles et les scories peuvent provoquer UN ENCENDIE e Oter tout combustible de l aire de coupe ou installer un d tecteur de flammes e Ne pas couper de r cipient ayant contenu des combustibles Tout mat
39. e to coated painted and other surfaces such as glass plastic and metal Handle torch leads with care and protect them from damage Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece Whenever possible avoid excessive pilot arc time to improve parts life 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 A specially designed shield cup attachment is available for drag cutting which allows the operator to keep the torch in contact with the workpiece during operation Drag cutting also requires special cutting tips For edge starts hold the torch perpendicular to the workpiece with the front of the tip on the edge of the workpiece 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 In the PCH M 35 torch 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 If dross is
40. ea that may be ignited by sparks e Do not mount this equipment over combustible surfaces Noise NOISE can cause permanent hearing loss e Wear proper protective ear muffs or plugs e Make sure others in the operating area are protected from noise Compressed Gas Compressed gas cylinders are potentially dangerous Cylinders Refer to suppliers for proper handling procedures iil INTRODUCTION IMPORTANT SAFETY PRECAUTIONS continued Publications The following publications provide additional information on safety precautions A Bulletin No C5 2 83 Recommended Safe Practices for Plasma Arc Cutting B American National Standard ANSI Z49 1 1983 Safety in Welding and Cutting Both publications are available from American Welding Society Inc 2501 Northwest 7th Street Miami Florida 33125 Telephone 305 443 9353 C OSHA Safety and Health Standards 29CFR1910 available from The U S Department of Labor Washington D C 20210 D CSA Standard W117 2 Safety in Welding Cutting and Allied Processes obtainable from The Canadian Standards Association 178 Rexdale Blvd Toronto Ontario M9W1R3 Canada E AS1674 AS2745 WITA Technical note 7 obtainable from Standards Australia s Quality Assurance Services 80 Arthur Street North Sydney N 5 W 2060 employer s safety practices A WARNING Read and understand this instruction manual and your INTRODUCTION iv PRECAUTIONS AVERT
41. eater than 100k ohms replace the wires which were removed from R1 and R2 and proceed 29 SERVICE 4 3 ADVANCED TROUBLESHOOTING continued The following table is a guide for analyzing problems and making repairs to the unit At this point make sure the input power selection connectors are plugged in correctly as in Section 2 2 and apply input power to the unit If at any point electrical arcing parts smok ing or burning or unknown noises occur immediately discon nect input power and return the unit to an authorized service center There are extremely dangerous voltage and power levels A WARNING Present inside this unit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques Once power is applied to the unit there are extremely hazard ous voltage and power levels present Do not touch any live parts and do not attempt to measure voltages on the output side of the high frequency transformer T2 or at the spark gap assembly The AC switch in the upper left corner of the front panel only turns control power on and off There are hazardous voltages present whenever input power is connected to the unit regardless of the position of the ON OFF switch SERVICE 30 Manual 0 2444 4 3 ADVANCED TROUBLESHOOTING continued SYMPTOM A No front panel LED indicators lit B AC indicator lit TEMP indicator red C AC indicator lit TEMP indicato
42. ectifiers must be tested If any are found to be failed all three must be replaced Testing Bridges Refer to Figure 4 A and locate BR2 and BR3 on the left hand side of the unit BR1 is located on the right hand side of the unit Set the digital volt meter to the diode voltage drop range NOTE All Measurements are made with the input wires attached to bridge rectifier terminals DO NOT bend terminals or remove wires to test This may weaken the diode and result in failure Each bridge rectifier BR1 BR2 and BR3 should read the same Terminal Reading to AC Av to AC Av to AC Av to AC Av to 7V Left Hand Side Input Bridge Rectifiers Located On Pilot Heat Sink Assembly Right Hand Side Input Bridge Rectifier SS Located On Main O i gt Zu Heat Sink Assembly red 11 7 1 blk blk 1 7 JL 13blk ls Edel Figure 4 A Input Rectifier Terminals SERVICE 36 Manual 0 2444 4 4 SERVICE PROCEDURES continued Replacing Bridge Rectifiers Input Capacitor Boards NOTE Manual 0 2444 Replacement input rectifier kits include three sets of bridge rectifiers with new thermal pads and mounting hardware When replacing the input rectifiers observe the following 1 Take extra care not to bend the rectifier terminals Push the connectors on with a single firm straight push Do not wiggle the connector as it is pushed on 2
43. ent sensor plugs from pilot and LDD if present PC boards 3 Remove the four screws which hold the mounting plate to the bottom chassis 23 ey gt JE Fan Assembly OC Main Transformer T3 Pilot Inductor L4 Work Lead Inductor L7 AWW 0 N E H e AA Regulator Solenoi Gauge Assembly Output Inductor Assembly L6 Spark Gap Assembly Figure 4 D Base Panel Component Locations SERVICE CA o Manual 0 2444 4 4 SERVICE PROCEDURES continued 4 Carefully remove the transformer from the unit 5 Install the replacement transformer by reversing the above procedure If the transformer has flat copper leads make sure the leads do not twist so that one could short against another Pilot Inductor L4 The only reason the pilot inductor should be replaced is if the cores are cracked due to shipping damage or the unit being dropped Minor chips are normal If any burning or arcing is visible on the pilot inductor return the unit to an authorized service center To remove the pilot inductor 1 Disconnect the wire from one lead of the pilot inductor and the connecting copper link from the other lead 2 Turn the unit on its side to access the two mounting nuts and lockwashers which attach it to the chassis Remove the inductor from the unit 3 Install the replacement inductor by reversing the above procedure To avoid damaging the core of the
44. hat input power is present and properly connected see Electrical Connections page 9 2 Check actual line voltage vs voltage selection on rear panel see Electrical Connections page 7 3 Check fuse on rear panel If blown doublecheck voltage selection and replace fuse If fuse blows again return unit to an authorized service station 4 Check and replace if necessary see Service Procedures page 42 1 Make sure the unit has not been operated beyond 70 duty cycle limit 2 Check for obstructed air flow see Service Proce dures page 43 3 Check and replace if necessary see Service Procedures page 42 1 Check that quick discon nect is properly attached 2 Check that shield cup is fully seated against torch head do not overtighten 3 Check PIP assembly 4 Check for continuity between pins 1 and 6 Check that pins in either half of quick disconnect are not pushed back SERVICE 4 2 POWER SUPPLY TROUBLESHOOTING continued SYMPTOM C continued D AC indicator lit TEMP indicator green PIP indicator lit GAS indicator not lit E When power is applied to unit GAS indicator remains lit for more than 20 seconds F Torch will not pilot when torch switch is activated SERVICE POSSIBLE CAUSE 5 Faulty LDD board 1 Gas not connected or pressure too low 2 Faulty pressure switch 3 Faulty regulator 4 Faulty LDD board 1 RUN SET switch in SET position 2
45. inder valves to be sure they are clean and free of oil grease or any foreign material Momentarily open each cylinder valve to blow out any dust which may be present 2 Each cylinder must be equipped with an adjustable high pressure regulator capable of pressures up to 125 psi 8 6 BAR maximum and flows of up to 700 scfh 328 lpm Refer to Figure 2 E page 12 and 3 Connect the 1 4 NPT adaptor fitting to the gas input fitting on the rear panel of the power supply 4 Connect the 1 4 NPT male side of the quick disconnect coupling to the adaptor fitting 5 Connect the supply hose from the high pressure regulator to the barb side of the quick disconnect coupling 6 Connect the quick disconnect coupling 11 INSTALLATION 2 4 GAS CONNECTIONS continued Using Shop Air An air line filter ordered separately is required when using air from a compressor to insure that moisture and debris from the supply hose does not enter the torch The LeMan two stage air line filter kit is recommended for most applications Follow the installation instructions for this kit on page 13 Air Line Filter Kit Two Stage Cat No 7 3340 Quick Disconnect Fitting 1 4 NPT Quick Disconnect Coupling 1 4 NPT to 6 Hose Fe ad CS Rear Panel Fitting Supply Hose from 1 4 NPT Source 6 Hose Figure 2 E Gas Connections INSTALLATION 12 Manual 0 2444 2 4 GAS CONNECTIONS continued
46. ing the power supply torch parts or torch and leads assemblies Refer to Figure 2 A and Remove the Hole Plug 1 Remove the hole plug from the hole marked REMOTE CONTROL on the upper left rear panel of the power supply Open the Enclosure 2 Locate the eight screws which hold together the two halves of the power supply enclosure Lay the power supply on its side with the screw heads facing UP Remove all eight mounting screws and carefully lift the upper half of the enclosure from the unit Lift the unit from the lower half of the enclosure and set the unit in upright position on a secure working surface continued on next page J6 Connector Remote Control J7 Connector Wire Harness Ground Wire Hole Marked A REMOTE CONTROL Pak Master Rear Panel m Ground Stud Inside Rear Panel A 00752 Figure 2 A Installing the RC Wire Harness Manual 0 2444 5 INSTALLATION 2 1 REMOTE CONTROL HARNESS INSTALLATION continued Install the Wire Harness ee CAUTION Reassemble the INSTALLATION Enclosure 3 Inside the power supply locate the white 6 pin connector J7 on the top panel close to the REMOTE CONTROL hole location 4 Connect the 6 pin plug on the remote control wire harness to the 6 pin connector J7 5 Locate the ground stud on the RIGHT side of the rear panel inside the panel at approximate center height Connect the ground wire of the remote control wire harness
47. l speeds may vary up to 50 from those shown Standoff Inches Standoff Inches Standoff Inches OPERATION OPERATION 22 Manual 0 2444 SECTION 4 CUSTOMER OPERATOR SERVICE 4 1 GENERAL POWER SUPPLY MAINTENANCE Routine Maintenance The only routine maintenance required for the power supply is a thorough cleaning and inspection with the frequency depending on the usage and the operating environment A WARNING Disconnect primary power to the system before disassembling the torch leads or power supply a CAUTION Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensi tive electrical components and cause damage to the unit To clean the unit open the enclosure see Service Procedures page 35 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 Manual 0 2444 23 SERVICE 4 2 POWER SUPPLY TROUBLESHOOTING Troubleshooting and repairing the Pak Master 50 power supply is a process which should be undertaken only by those familiar with high voltage high power electronic equipment inside this unit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques There are extremely dangerous voltage and power levels present
48. low ees CAUTION es CAUTION Checking Air Quality Filtering Gas Connections Using High Pressure Gas Cylinders Manual 0 2444 Compressed Air or Nitrogen N2 Only 70 psi 4 8 BAR Cutting 200 scfh 94 4 lpm Gouging 230 scfh 108 5 lpm Max input pressure must not exceed 125 psi 8 6 BAR 860 kPa Air supply must be free of oil moisture and other contaminants Excessive oil and moisture may cause double arcing rapid tip wear or even complete torch failure Contaminants may cause poor cutting performance and rapid electrode wear To test the quality of air place a welding filter lens in front of the torch and turn on the gas Any oil or moisture in the air will be visible on the lens Do not initiate an arc An air line filter not included is required when using air from a compressor to insure that moisture and debris from the supply hose does not enter the torch The filter must be capable of filtering to at least 5 microns For highly automated applications a refrigerated drier may be used The rear panel of the power supply is equipped with a 1 4 NPT gas input fitting A quick disconnect coupling 1 4 NPT to 6 barb is supplied with the unit Refer to the manufacturer s specifications for installation and maintenance procedures for high pressure gas regulators Do not use an air line filter with high pressure gas cylinders To use air or nitrogen from a high pressure gas cylinder 1 Examine the cyl
49. make sure the studs on the bottom of the panel enter the holes in the top of the heatsinks Some slight wiggling of the heatsinks may help this alignment Tighten the panel mounting nuts to just short of fully tight and measure the distance between the middle and top panels Move the panel slightly until this distance is 4 1 16 inches from the top of the middle panel to the top of the top panel Tighten the mounting screws the rest of the way Check this measurement again because if it is off you will have difficulty reassembling the enclosure 9 Install the LDD board and remount the input block to the top panel 43 SERVICE 4 4 SERVICE PROCEDURES continued SERVICE K1 Pilot Relay Reassembling the Enclosure D9 indictes the status of K1 pilot relay and is located on the back of the pilot board In order to view the LED you must use a mirror in behind the heatsink assembly towards the front of the machine D9 is lit when the unit is cutting D9 is off when the unit is piloting Before reassembling the power supply enclosure check that all wire harnesses and ribbon cables fit into the notches in the edge of the top and middle panels so that wires don t get pinched 1 With the unit in an upright position tip the unit so that one of the case halves may be slid onto the chassis Then lift the unit and set it down on the side with the case half down 2 Before installing the other case half make sure the edges of the bott
50. manuel d instructions ainsi que les pratiques sur la securite emises par votre employeur vii INTRODUCTION 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 recommen dations 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
51. minants from the air stream when using compressed air 575V Transformer Unit Cat No 9 6211 For operating standard systems with 575V three phase input e Spare Parts Kit Standard Cutting sese esse Cat No 5 6001S Spare Parts Kit Gouging anni Cat No 5 6015 Spare Parts Kit Long Life nn Cat No 5 6001 Kits contain replacement front end torch parts see detailed description of spare parts kit contents on page 72 Leads Extension Kit PCH 35 25 ft 7 6 m Cat No 4 6007 Leads Extension Kit PCH 35 50 ft 15 2 m Cat No 4 6008 Leads Extension Kit PCM 35 25 ft 7 6 m Cat No 4 6009 Leads Extension Kit PCM 35 50 ft 15 2 m Cat No 4 6010 For extending torch leads up to 150 ft 45 7 m Phenolic Mounting Tuben ne Cat No 7 3251 Phenolic Pinch Block Mounting Assembly Cat No 7 3252 For machine mounted torch applications where a non metal mounting assembly is desired Switch Lever Kit Cat No 8 5170 Provides a lever for activating the hand torch control switch Refer to Section 5 Parts Lists for ordering information 4 Manual 0 2444 SECTION 2 INSTALLATION 2 1 REMOTE CONTROL HARNESS INSTALLATION Installation of the remote control RC wire harness is required for machine torch systems Installation requires four 6 32 screws with locknuts RC Wire Harness Disconnect primary power at the source before assembling or WARNING disassembl
52. necting lug Keep it away from other compo nents and sheet metal as it has very high voltages on it and it can emit electrical interference into critical circuitry 2 Install a replacement HF inductor and connect 41 SERVICE 4 4 SERVICE PROCEDURES continued Solenoid Regulator Gauge Assembly Checking the LDD Board Replacing the LDD Board SERVICE To check the solenoid measure for 115 VAC between wires 18 and 21 If 115 VAC is present replace the solenoid 1 Disconnect the two connecting hoses by pushing the slip ring at the end of each quick disconnect fitting toward the fitting and holding while pulling on the hose 2 Disconnect the four wires from the pressure switch and solenoid 3 If present remove the two mounting screws through the front panel and the regulator nut and remove the assembly 4 Install a new assembly on the front panel and reattach the hoses by pushing the hose into the fitting until it stops about 3 8 inch penetration 5 Reconnect the wires to the pressure switch and solenoid To check the Log Gate Drive Display LDD PC board assembly measure for 15 18 VAC from J1 9 to J1 7 and from J1 9 to J1 6 If 15 18 VAC is present replace the LDD board Since the LDD board contains no high power circuitry but does contain all the controlling logic for the unit many problems could be caused by a faulty board Never replace the LDD board to try to fix a problem if there is any evidence
53. om middle and top chassis panels are fully inserted into the slots in the case Look for gaps between the front and rear panels and the edge of the case and look into the case to see that the notches in the top corners of the front and rear panels are flush against the plastic stops of the case It may take some lifting and re settling of the chassis to get this all lined up 3 Once the chassis is properly aligned in one case half gently lower the other half onto the other side of the chassis by tipping it slightly so that the top is slightly lower than the bottom Then push and gently tap down until the two case halves are within 1 16 inch If you have trouble getting the case halves close enough remove the top half and check to see that the bottom half is fully engaged and that there are no wires out of place on the top and middle panels 4 Install the eight screws lockwashers and nuts to finish the assembly 44 Manual 0 2444 SECTION 5 PARTS LISTS 5 1 ORDERING INFORMATION Manual 0 2444 Ordering Information by the catalog number shown ics without proper authorization will not be accepted 45 About the Parts List Description Figure Page 5 2 Complete System Replacement ee 46 5 3 Front Panel Components sees eee eee Figure 5 A 47 54 Regulator Solenoid Assembly 112 Figure 5 B 48 5 5 Base Panel Components s sss1ssssss11ss11111 Figure 5 C 49 5 6 Chassis Components
54. plug is optional Machine torch systems also include a remote hand control and remote control wire harness PCH M 35 Torch with Leads Packaged Separately The torch provides a maximum 1 2 inch 12 mm cut capacity Hand torches are available in 70 and 90 configurations which include a handle and multi position switch assembly Machine torches include a rack and pinion mounting assembly A phenolic plastic pinch block mounting assembly is optional Torch leads are available in 12 5 25 or 50 ft 3 8 7 6 or 15 2 m lengths with a quick disconnect torch leads fitting for simple installation The PCH M 35 includes a spare parts kit which provides an assortment of replacement consumable torch parts e See page 4 for a list of other system options and accessories Pak Master 50 Power Supply f gt Ee Torch with Leads Work Cable with Clamp A 00750 Figure 1 A System Components Manual 0 2444 1 GENERAL INFORMATION 1 2 SPECIFICATIONS Controls ON OFF Switch RUN SET Switch Output Current Control Corner Slowdown Control Pressure Regulator Control Panel Indicators LED Indicators AC Power TEMP PIP Parts In Place GAS DC Power PILOT Pressure Gauge Input Power 200 to 460 VAC 10 50 or 60 Hz Single or Three Phase 575V Additional Transformer Required Catalog No 9 621 1 Output Power Continuously variable from 15 to 35 Amps maximum 70 Duty Cycle
55. 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 19 OPERATION 3 4 OPERATING THE SYSTEM continued Dross High speed dross usually forms a narrow bead along the bottom continued 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 Common Cuiting Faults Problem Possible Cause Cutting speed too fast Torch tilted too much Metal too thick Worn torch parts Cutting current too low Insufficient Penetration Cutting speed too slow Torch standoff too high from workpiece AC line too low reduce output current Work cable disconnected Worn torch parts Main Arc Extinguishes Cutting speed too slow bottom dross Easily removed Excessive Cutting speed too fast bottom dross Tight bead Difficult to remove Dross Formation Torch standoff too high from workpiece top dross Easily removed Worn torch pa
56. r green PIP indicator not lit Manual 0 2444 POSSIBLE CAUSE 1 ON OFF switch OFF 2 AC from control trans former T1 not present blown fuse incorrect voltage selection or faulty control transformer 3 Faulty LDD board 1 Unit is overheated 2 Faulty LDD board 3 Shorted thermal sensor on FET or pilot assembly 1 Torch not properly con nected or shield cup not in place 2 Faulty pins in torch quick disconnect 3 Faulty LDD board 4 Faulty wiring to torch or torch connector 31 REMEDY 1 Turn ON OFF switch to ON position 2 Slide plastic cover off top of connector J1 on LDD board Measure 18 VAC from J1 6 to J1 9 and the same from J1 7 to J1 9 If 18 VAC is not present a check fuse b check for proper voltage selection c check T1 connectors If still no voltage replace control transformer T1 3 Replace LDD board m Allow time for unit to cool If TEMP indicator is still red after unit has cooled replace LDD board D 3 Return unit to authorized service center 1 Check torch quick discon nect and torch parts for proper assembly 2 With power off check continuity between J1 17 and J1 18 If no continuity check PIP wires 3 Measure voltage between J1 17 and J1 18 If less than 1 volt replace LDD board 4 Check wiring to torch and torch connector from J1 17 and J1 18 to Quick Discon nect QD SERVICE 4 3 ADVANCED TROUBLESHOOTING GUIDE continue
57. rews AA SA A X TI bk 4 N 1 SORS AT N NIE Se A 00754 T Single Circuit Plug Figure 2 B Input Voltage Selection 7 INSTALLATION 2 2 ELECTRICAL CONNECTIONS continued mu CAUTION Both input voltage settings on the power supply must correspond to the actual primary input voltage Input Power Cable Systems ordered for 230V operation come supplied with a 230V Connections single phase input power cable attached For any other input voltage the 230V input power cable must be removed and replaced with an appropriate power cable A WARNING Disconnect primary power at the source before disassembling the power supply torch or torch leads Refer to Figure 2 C page 9 and 1 Remove the access panel on the rear panel of the unit and disconnect the factory installed 230V input power cable Loosen the strain relief and remove the cable NOTE Input power connections can be made directly to a properly fused disconnect or by using a plug which conforms to the recommended ratings Me CAUTION The primary power source power cable and plug all must conform to local electric code and the recommended circuit protection and wiring requirements see Table 2 A page 9 2 Before connecting the replacement input power cable strip back the outer covering approximately 3 inches 76 mm to expose the individual wires Then cut back the insulation on the individual wires approximately 1 8 3 1
58. riel inflammable ou combustible pouvant tre allum par une tincelle doit tre enlev de l aire de coupe vi PRECAUTIONS continuer Le bruit Bouteilles de gaz comprimes Les publications AVERTISSEMENT A LE BRUIT peut causer la surdit e Prot des protecteurs auditifs e Assur que tous les autres sont prot g du bruit LES RESERVOIRS DE GAZ SONT DANGEREUX Se r f rer aux directives du constructeur pour une bonne utilisation LES PUBLICATIONS suivantes contiennent des renseigne ments suppl mentaires sur les pr cautions a prendre pour garantir la s curit A Bulletin No C5 2 83 Recommended Safe Practices for Plasma Arc Cutting B American National Standard ANSI Z49 1 1983 Safety in Welding and Cutting Vous pouvez vous les procurer toutes les deux aupres de American Welding Society Inc 2501 Northwest 7th Street Miami Florida 33125 U S A T l phone 305 443 9353 C OSHA Safety and Health Standards 29CFR 1910 disponible aupres du U S Department of Labor Washington DC 20210 USA D Norme de l ACNOR W117 2 Safety in Welding Cutting and Allied Processes que l on peut obtenir aupres de L Association Canadienne Des Normes 178 Rexdale Blvd Toronto Ontario Canada M9W 1R3 E AS1674 AS2745 WITA Technical note 7 obtainable from Standards Australia s Quality Assurance Services 80 Arthur Street North Sydney N 5 W 2060 Lire et comprendre ce
59. rts Improper cutting current Oil or moisture in air source Exceeding system capability material too thick Excessive pilot arc time Air flow too low incorrect pressure Improperly assembled torch Short Torch Parts Life Table 3 C Common Causes of Operating Problems OPERATION 20 Manual 0 2444 3 5 RECOMMENDED CUTTING SPEEDS Thickness Inches Thickness Inches Thickness Inches Manual 0 2444 Voltage Amperage Volts Amps Speed Per Minute Inches Meters Table 3 D PCM 35 Cutting Speeds Air Plasma on Mild Steel Voltage Amperage Volts Amps Speed Per Minute Inches Meters Table 3 E PCM 35 Cutting Speeds Air Plasma on Aluminum Voltage Amperage Volts Amps Speed Per Minute Inches Meters Table 3 F PCM 35 Cutting Speeds Air Plasma on Stainless Steel NOTE Speed performance shown for the 9 6500 Tip is the same as the 9 6000 Tip 21 Recommended Cutting speed depends on material thickness and the operator s Cutting Speeds ability to accurately follow the desired cut line The following factors may have an impact on system performance e Torch parts wear e Air quality e Line voltage fluctuations e Torch standoff height e Proper work cable connection NOTE This information represents realistic expectations using recom mended practices and well maintained systems Actua
60. s supply on 5 Move the ON OFF switch to ON position When the unit is switched on an automatic 20 second pre flow gas purge will remove any moisture that may have accumulated in the torch and leads while the system was shut down The torch cannot be activated during pre flow After 20 seconds if the RUN SET switch is in SET position gases will flow If the RUN SET switch is in RUN position there will be no gas flow 6 Select the desired current output level 15 to 35 amps 7 Move the RUN SET switch to SET position Adjust the gas pressure to 70 psi 4 8 BAR 8 Set the RUN SET switch to RUN position The system is now ready for operation 17 OPERATION 3 3 SEQUENCE OF OPERATION ACTION Close external ON OFF switch disconnect switch to ON RESULT RESULT AC TEMP PIP indicators on Fan on Pilot disabled during 20 second pre flow ACTION Power to system ACTION Protect eyes and activate torch RESULT Gas flows GAS indicator on After gas pre flow DC indicator on Power supply enabled HF relay closes Pilot arc established PILOT indicator on ACTION Torch deactivated by torch switch release or by remote device RESULT Main arc stops Pilot stops Power supply enable signal removed DC indicator off PILOT indicator off ACTION RUN SET switch to SET RESULT Gas solenoid open gas flows to set pressure GAS indicator on PILOT ARC ACTION RUN SET
61. screw 8 Reconnect J1 J2 J4 and J5 The connectors all go in one way only except Jl Make sure J1 is connected so both ends of the cable half of the connector line up with the ends of the board mounted connector 9 Turn the shaft of the pot all the way clockwise and reattach the knob by tightening the screw with the line on the knob at the straight down position The fan assembly consists of a rotary fan an attached spacer plate and a foam seal To replace the fan assembly 1 Remove the LDD board to expose the top panel 2 Remove the two nuts which hold the input connection block from the top panel Move the input block and its mounting panel up out of the way 3 Remove the four nuts which hold the top panel to the front and rear panel and lift the top panel to allow the fan assembly to be removed by lifting it out 4 Remove the old fan by removing the two wires from the fan terminals and removing the four mounting screws from the rear panel A small socket wrench or needlenose pliers may be necessary to hold the nuts while removing the screws 5 Replace with a new fan assembly Slide the assembly in gently so that the foam seal doesn t catch and seals tightly against the heatsinks 6 Place the fan guard on the outside of the unit and reinstall the four fan mounting screws and nuts 7 Connect the two wires back onto the fan terminals polarity doesn t matter 8 Put the top panel onto its mounting studs and
62. switch to RUN RESULT Gas flow stops GAS indicator off Power circuit ready ACTION Torch moved away from work while still activated RESULT Main arc stops Pilot arc auto matically restarts PILOT indicator on ACTION Torch moved within transfer distance of workpiece RESULT Main arc transfer Pilot arc off PILOT indicator off DC indicator still on NOTE If torch is activated during post flow pilot arc will immediately restart If torch is within transfer distance 3 8 in of workpiece main arc will transfer After post flow ACTION ON OFF switch to OFF RESULT ACTION Open external disconnect RESULT Gas solenoid closes gas flow stops GAS indicator off All indicators off Power supply fan off No power to system A 00021 Figure 3 B Sequence of Operation OPERATION 18 Manual 0 2444 3 4 OPERATING THE SYSTEM A WARNING A WARNING ee CAUTION NOTE Piloting Torch Standoff Edge Starting Direction of Cut Dross Manual 0 2444 Disconnect primary power at the source before disassembling the power supply torch or torch leads Frequently review the Important Safety Precautions page ii 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 acti vated Sparks from the cutting process can cause damag
63. 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 STAK PAK II 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 following further limitations on such two 2 year period The limited warranty period for STAK PAK II 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 following further limitations on such three 3 year period PARTS PAK UNITS POWER SUPPLIES STAK PAK II All OTHERS LABOR MAIN POWER MAGNETICS 3 YEARS 2 YEARS ORIGINAL MAIN POWER RECTIFIER 3 YEARS 2 YEARS CONTROL PC BOARD nine 3 YEARS 2 YEARS ALL OTHER CIRCUITS AND COMPONENTS neee 1 YEAR
64. ve screws at the top of the unit and the three screws at the bottom which hold the two halves of the enclosure together Save all the screws nuts and lockwashers for reassembly 2 With the unit in an upright position carefully separate the two halves of the enclosure Leave the input power source disconnected from the unit during the visual inspection 3 Visually inspect the inside of the power supply The high levels of power present in the unit can cause burning or arcing of components and PC boards when a failure occurs Carefully inspect all components on the base bottom panel and the pilot and FET PC boards Look in particular for the following e Loose or broken wires or connectors e Cracked or broken cores on the high frequency magnetics T3 L4 and L6 Burned or scorched parts or wires or evidence of arcing e Any accumulation of metal dust or filings which may have caused shorting or arcing SERVICE 28 Manual 0 2444 4 3 ADVANCED TROUBLESHOOTING continued Manual 0 2444 If any parts are damaged they must be replaced Listed here are the subassemblies which are replaced if they are seen to be damaged or if they are found to be faulty If other subassemblies are obviously damaged or if the problem cannot be located the unit must be returned to an authorized service center Input Bridge Rectifiers BR1 BR2 BR3 Input Capacitor Boards Main FET Heatsink Assembly Main Transformer T3 Pilot Inductor

A THERMADYNE® Company PAK MASTER

Contents

Download Pdf Manuals

Related Search

Related Contents

A THERMADYNE&reg; Company PAK MASTER

Contents

Download Pdf Manuals

Related Search

Related Contents

A THERMADYNE® Company PAK MASTER