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Thermadyne Thermal Dynamics PAK MASTER 50XL Service Manual

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PAK MASTER
50XL
Air Plasma Cutting
Power Supply
A-01324
Service Manual
Manual No. 0-2587
August 11, 1999

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Summary of Contents for Thermadyne Thermal Dynamics PAK MASTER 50XL

  • Page 1 ® PAK MASTER 50XL Air Plasma Cutting Power Supply A-01324 Service Manual Manual No. 0-2587 August 11, 1999...
  • Page 3 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. ®...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ....................1 1.01 Notes, Cautions and Warnings ..............1 1.02 Important Safety Precautions ................ 1 1.03 Publications ....................2 1.04 Note, Attention et Avertissement ..............3 1.05 Precautions De Securite Importantes ............3 1.06 Documents De Reference ................
  • Page 5 TABLE OF CONTENTS (continued) SECTION 6: PARTS LISTS ........................37 6.01 Introduction ....................37 6.02 Ordering Information ..................37 6.03 Major External Replacement Parts List ............38 6.04 Access Panel Replacement Parts List ............40 6.05 Front Panel Replacement Parts List ............. 42 6.06 Left Side Internal Component Replacement Parts List ........

  • Page 7: General Information

    SECTION 1: GASES AND FUMES GENERAL INFORMATION Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Throughout this manual, notes, cautions, and warnings Keep your head out of the welding fume plume.

  • Page 8: Publications

    • Install and maintain equipment according to NEC • To protect your eyes, always wear a welding hel- code, refer to item 9 in Subsection 1.03, Publica- met or shield. Also always wear safety glasses with tions. side shields, goggles or other protective eye wear. •...

  • Page 9: Note, Attention Et Avertissement

    8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PRO- AVERTISSEMENT CESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, Toute procédure pouvant provoquer des blessures obtainable from the National Fire Protection Asso- de l’opérateur ou des autres personnes se trouvant ciation, Batterymarch Park, Quincy, MA 02269...
  • Page 10 • Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des INCENDIE ET EXPLOSION revêtements se trouvant sur le métal et des différents procédés. Vous devez prendre soin lorsque vous Les incendies et les explosions peuvent résulter des scories coupez ou soudez tout métal pouvant contenir un chaudes, des étincelles ou de l’arc de plasma.

  • Page 11: Documents De Reference

    • Utilisez la nuance de lentille qui est suggèrée dans 4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA le recommendation qui suivent ANSI/ASC Z49.1: PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de Nuance Minimum Nuance Suggerée Courant Arc Protective Numéro...
  • Page 12 14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRA- TIQUES SURES POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126 15.

  • Page 13: Declaration Of Conformity

    Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture. Manufacturers responsible representative: Steve Ward Director of Operations Thermadyne UK Chorley England Date: 6/22/99 GENERAL INFORMATION...

  • Page 14: Statement Of Warranty

    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...

  • Page 15: Introduction

    SECTION 2: 2.03 Service Responsibilities INTRODUCTION The Service Technician should be familiar with the equip- ment and its capabilities. He should be prepared to rec- ommend arrangements of components which will pro- 2.01 Scope Of Manual vide the most efficient layout, utilizing the equipment to its best possible advantage.
  • Page 16 INTRODUCTION Manual 0-2587...

  • Page 17: Description

    m) lengths with fittings for simple installation. The torch SECTION 3: includes a spare parts kit which provides an assortment DESCRIPTION of replacement torch parts. NOTE 3.01 Scope Refer to Section 3.04 for list of power supply op- tions and accessories. The information in this Section has two purposes: 3.03 Specifications/Design Features •...

  • Page 18: Power Supply Options And Accessories

    10. Overall Dimensions D. Smart Cart 18.9" (480 mm) High x 13" (330 mm) Wide x 23.5" (597 Steel cart on easy rolling 10" pneumatic tires to pro- mm) Long vide maximum mobility for the power supply. Handle is 3/4" tubing with hooks for storage of torch leads. Overall dimensions are with handle, lead wrap A tie down strap is also included.

  • Page 19: Service Troubleshooting Diagnostics

    SECTION 4: CAUTION SERVICE Sparks from the cutting process can cause damage TROUBLESHOOTING to coated, painted, and other surfaces such as glass, plastic and metal. DIAGNOSTICS NOTE Handle torch leads with care and protect them from 4.01 Introduction damage. A. Piloting This Section provides service diagnostics for the Pak Master 50XL Power Supply, allowing the Technician to Piloting is harder on parts life than actual cutting be-...

  • Page 20: Troubleshooting Guide - General Information

    it is sometimes useful to reduce the cutting speed to 4.04 Troubleshooting Guide - produce "slow speed dross". Any resultant cleanup General Information can be accomplished by scraping, not grinding. F. Common Cutting Faults WARNING 1. Insufficient Penetration a. Cutting speed too fast There are extremely dangerous voltage and power b.

  • Page 21: Circuit Fault Isolation

    C. How to use the Troubleshooting Guide Set the Power Supply controls as follows: ON/OFF switch to OFF The following information is a guide to help the Service Technician determine the most likely causes for various RUN/SET switch to SET symptoms.

  • Page 22: Main Input And Internal Power Problems

    5. Improper input power line connections inside Power D. Main Arc Test Supply Press the Torch Switch to establish a pilot arc. a. Refer to Operating Manual 0-2586, Section 3.07 Bring the torch to within 1/8"-3/8" (3.2 - 9.5 mm) of the and correct if needed workpiece to establish the main cutting arc, and note the 6.
  • Page 23 13. Faulty Gate Drive PC Board (refer to Appendix XI, 2. Gas supply not connected to unit 36 V AC Circuit Diagram) a. Connect to gas supply Measure for 36 VAC on Gate Drive PC Board from 3. Gas supply not turned on J9-1 to J9-3.
  • Page 24 Pin 9 Pin 8 TP1 (GND) Logic PC Board Logic PC Board A-01392 4. Faulty Pilot Output PC Board Remove power from the power supply. Discon- Pin 13 nect J12 and J13 from the Pilot PC Board. A-01391 Check for an open between J12 pin 1 to J12 pin 3 on the Pilot Output PC Board.

  • Page 25: Pilot Arc Problems

    C. AC indicator ON; Gas flows; GAS and DC 4.07 Pilot Arc Problems indicators ON; No arc in torch; No arc at spark gap on CD PC Board; CD enable indicator (D15) Locate your symptom below: on CD PC Board ON A.

  • Page 26: Main Arc Problems

    3. Faulty current sensor Check the following indicators inside the Power Pilot Output PC Board Supply: • Pilot indicator (D33) on the Logic PC Board is ON during pilot then OFF during main arc transfer • CSR indicator (D31) on the Logic PC Board is OFF during pilot then ON during main arc transfer A-01400...
  • Page 27 6. Misaligned plugs can cause printed circuit board dam- C. Diode Testing Basics age. Be sure plugs are properly aligned and com- Testing of diode modules requires a digital volt/ohmme- pletely seated. ter that has a diode test scale. Remember that even if the 7.
  • Page 28 Remove AC power and with an ohmmeter set on the di- A-00306 ode range make the following checks: Meter (+) Meter (-) Indication Diode Drop Open Reverse Bias Diode Not Conducting Diode Drop Open Diode Drop VR COM Open Cathode Open Diode Drop Open...
  • Page 29 If indicator D34 is OFF check for proper AC input volt- 6. Disconnect ribbon cable from the Lower FET/ age per the following: Heatsink Assembly at J6. 7. Place the front panel ON/OFF switch to ON. • Single Phase Units check at L1 and L2 8.
  • Page 30 13. Reconnect the ribbon cables to the Upper and The indicators on the Logic PC Board as follows: Lower FET/Heatsink Assemblies at J6. 14. If the front panel TEMP indicator is still ON, re- place the Logic PC Board. G. Gas Solenoid Circuit Test Make the following voltage checks per the circuit dia- gram and replace the faulty part as required.
  • Page 31 The indicators on the Gate Drive PC Board as follows: this point the gas begins to flow. When the preflow time is over the PWM Enable signal is given and the DC indicator at the front panel turns ON. When the POWER ENABLE pilot arc is established the Pilot On indicator, D33, turns ON.
  • Page 32 b. Connect a jumper between TP1 and one of the This will cause the gas to flow continuously following points depending on the style of the and the DC indicator on the front panel to turn Logic PC Board in the unit: NOTE WARNING To determine the style of the Logic PC Board note...
  • Page 33 If the checks indicate open or shorted in both direc- d. Place the meter (+) lead on drain lead of Q1 and tions then the faulty Fet/Heatsink Assembly should meter (-) lead to the heatsink. The meter should be replaced. indicate >1 meg ohms.
  • Page 34 NOTE A-01423 The wires on E16 and E18 should still be discon- nected from both FET/Heatsink Assemblies. a. Place the meter (+) lead on E17 and the meter (-) lead on E18 of the FET/Heatsink Assembly to check the output clamp diode resistance. The meter should indicate >1 meg ohms.

  • Page 35: Repairs & Replacement Procedures

    2. Unroll the rest of the band and peel the liner from SECTION 5: the copper foil at the opposite end. REPAIRS & REPLACEMENT 3. Attach the copper foil to a convenient and exposed electrical ground. PROCEDURES 4. Connect the equipment primary cable ground to the same electrical ground as the wrist strap.

  • Page 36: Major External Parts Replacement

    Before disassembling any part of the Power Supply first 4. Remove the four screws securing the Leads Wrap read the procedure for the part to be replaced, then pro- to the old Left Side Panel. ceed with the disassembly. 5. Install the replacement Left Side Panel by revers- ing the above procedure noting the following: 5.04 Major External Parts •...

  • Page 37: Access Panel Parts Replacement

    5. Remove the Pot/LED PC Board from the four stand- 5.05 Access Panel Parts offs. Replacement 6. Disconnect the connector at J14 of the Pot/LED PC NOTE Board. Refer to Section 6.04 for parts list and overall detail draw- 7. Install the replacement Pot/LED PC Board by re- ing.

  • Page 38: Left Side Internal Component Parts Replacement

    10. Install the replacement Work Cable by reversing e. On the right side remove the three nuts and the above procedure. washers securing the internal chassis to the bot- tom of the unit. B. Main Contactor Replacement 7. At the front panel remove the two screws securing 1.
  • Page 39 NOTE 5. Install the replacement Logic PC Board by revers- ing the above procedure. Failure to properly tighten the seven screws secur- ing the Input PC Board to the Diode Bridge will F. Gate Driver PC Board Replacement cause damage to the unit. 1.

  • Page 40: Rear Panel Parts Replacement

    3. Remove the Ribbon Cable plug at J6 on the FET/ A. Two Stage Air Line Filter Replacement Heatsink Assembly. To remove the cable, push NOTE down on the locking tab and pull the cable plug out of the connector. This part is an option and may not be installed on all units.

  • Page 41: Right Side Internal Component Parts Replacement

    3. Remove the four screws securing the Air Line Regu- 4. Install the replacement Pilot/Output PC Board As- lator Bracket to the Rear Panel. sembly by reversing the above procedure. 4. Pull the bracket from the unit. B. CD PC Board Assembly Replacement 5.
  • Page 42 4. On the voltage selection panel remove the pin 13 from connectors J19 (black wire), J20 (orange wire), C o n n e c t io n D e sc rip t io n and J21 (brown wire) using a pin removal tool . E 1 4 M A I N X F M R P R I 5.

  • Page 43: Parts Lists

    SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts lists provide a breakdown of all replaceable components. The parts lists are arranged as follows: Section 6.03 Major External Replacement Parts List Section 6.04 Access Panel Replacement Parts List Section 6.05 Front Panel Replacement Parts List Section 6.06 Left Side Internal Component Re- placement Parts List...

  • Page 44: Major External Replacement Parts List

    6.03 Major External Replacement Parts List Item # Description Catalog # TUBE, LIFTING HANDLE, 1.125 OD, 11.85 LG 9-7505 MOUNT, LIFTING HANDLE 9-7506 COVER, LEFT SIDE Includes: 9-7583 COVER, LEFT SIDE, LABEL, USER WARNING, ENGLISH COVER, RIGHT SIDE Includes: 9-7584 COVER, RIGHT SIDE OVERLAY, RIGHT SIDE PANEL LABEL, USER WARNING, FRENCH...
  • Page 45 A-01381 Manual 0-2587 PARTS LISTS...

  • Page 46: Access Panel Replacement Parts List

    6.04 Access Panel Replacement Parts List Item # Description Catalog # ASSEMBLY, POT/LED PCB Replacement Kit (PC Board & Knob) 9-7014 KNOB, INNER CONCENTRIC Current Pot Shaft Diameter 1/8 inch - Order Kit 9-7014 Current Pot Shaft Diameter 1/4 inch - Knob Only 9-8007 ON/OFF ROCKER SWITCH, DPST 8-3258...
  • Page 47 A-01065 Manual 0-2587 PARTS LISTS...

  • Page 48: Front Panel Replacement Parts List

    6.05 Front Panel Replacement Parts List Item # Description Catalog # BASE/FRONT, UNIT Includes: 9-7587 BASE/FRONT, UNIT GROUND TAG 8-4243 USA LABEL (1 3/4 X 3) 8-3216 OVERLAY, FRONT PANEL 9-7593 CONTACTOR, 3 POLE, 40 FLA, 600 VAC 9-7554 STRAIN REFIEF, FOR #10 STRANDED WIRE 8-4249 FAN, 115V, 50/60HZ, 95/115CFM W/.187 TABS 8-3209...
  • Page 49 A-01382 Manual 0-2587 PARTS LISTS...

  • Page 50: Left Side Internal Component Replacement Parts List

    6.06 Left Side Internal Component Replacement Parts List Item # Description Catalog # INSULATOR, INPUT PCB See Note 1 CABLE ASSEMBLY, 10 CIR RIBBON, 15"LG 9-5922 CABLE, 20 CIRCUIT RIBBON 9-7510 LOGIC CONTROL PCB ASSEMBLY 9-7563 ASSEMBLY, GATE DRIVER PCB 9-7562 ASSEMBLY, FET HEATSINK Includes: 9-7560...
  • Page 51 To J10 On Logic PCB To Input A-01420 Manual 0-2587 PARTS LISTS...

  • Page 52: Rear Panel Replacement Parts List

    6.07 Rear Panel Replacement Parts List Item # Description Catalog # PRESSURE SWITCH-35 PSI 9-1044 VALVE, SOLENOID 1/8 NPT 8-3370 REGULATOR, AIR LINE 9-7514 FLEX CONNECTOR 8-4289 1/4 NPT STREET ELBOW 9-2184 1/8 NPT STR.TEE 8-0352 1/4-1/8 NPT REDUCER 9-2023 FITTING, 1/8 NPT X 2"...
  • Page 53 A-01068 Manual 0-2587 PARTS LISTS...

  • Page 54: Right Side Internal Component Replacement Parts List

    6.08 Right Side Internal Component Replacement Parts List Item # Description Catalog # BULKHEAD ADAPTER, O2B - 1/8 NPT 9-4045 9/16-1/8 JAM NUT 8-2149 CHASSIS, CENTER See Note 1 PANEL, PILOT ASSEMBLY MOUNTING See Note 1 BRACKET, BULKHEAD MOUNTING See Note 1 INSULATOR, BULKHEAD See Note 1 PCR RELAY, DPST-NO, 25A @ 250V, 12VDC COIL...
  • Page 55 A-01383 Manual 0-2587 PARTS LISTS...

  • Page 56: Options And Accessories

    6.09 Options and Accessories Description Catalog # Smart Cart 7-7777 Interface Cable - For Use With Machine Torches Only 25 foot (7.62m) 8-5557 50 foot (15.24m) 8-5558 575V Transformer 9-7500 220V Single-Phase Input Power Cable 8-4384 Circle Cutting Attachment 7-3291 PARTS LISTS Manual 0-2587...

  • Page 57: Appendix I: Input Wiring Requirements

    APPENDIX I: INPUT WIRING REQUIREMENTS In p u t P o w er In p u t C u r r en t S u g g ested S iz es (S ee N o tes) V o ltag e F r eq .

  • Page 58: Appendix Ii: Sequence Of Operation (Block Diagram)

    APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION ACTION ACTION ACTION ON/OFF switch Close external RUN/SET switch RUN/SET switch to ON. disconnect switch. to RUN. to SET. RESULT RESULT RESULT RESULT AC indicator blinks for 8 Power to system. Gas flow stops. Gas solenoid open, seconds then steady on.

  • Page 59: Appendix Iii: Pot/Led Pc Board Layout

    APPENDIX III: POT/LED PC BOARD LAYOUT A-01206 Pot/LED PC Board Signals J14-1 +10 vdc from Logic PC Board (J3-7) J14-2 Current Control to Logic PC Board (J3-8) J14-3 Return for Current Control from Logic PC Board (J3-9) J14-4 +12 VDC from Logic PC Board (J3-10) J14-5 Signal for AC OK Indicator to Logic PC Board (J3-11) J14-6...

  • Page 60: Appendix Iv: Logic Pc Board Layout

    APPENDIX IV: LOGIC PC BOARD LAYOUT Current Sensor A-01388 Logic PC Board Signals J1-1 36 VAC from Auxiliary Transformer J3-1 36 VAC to ON/OFF Switch J1-2 115 VAC from Auxiliary Transformer J3-2 36 VAC from ON/OFF Switch to Logic PC Board J1-3 Center Tap from Auxiliary Transformer J3-3...
  • Page 61 J4-1 36 VAC from Gate Driver PC Board (J9-1) J4-2 36 VAC to Gate Drive PC Board (J9-2) J4-3 36 VAC from Gate Drive PC Board (J9-3) J4-4 36 VAC to Gate Drive PC Board (J9-4) J4-5 Ground to Gate Drive PC Board (J9-5) J4-6 36 VAC to Gate Drive PC Board (J9-6) J4-7...

  • Page 62: Appendix V: Gate Drive Pc Board Layout

    APPENDIX V: GATE DRIVE PC BOARD LAYOUT RESET TP11 TP12 POWER ENABLE TP13 A-01205 Gate Drive PC Board Signals J7-1 +12 VDC to FET PC Boards (J6-1) J7-2 Return for +12 VDC to FET PC Boards (J6-2) J7-3 PWM Output (A) to FET PC Boards (J6-3) J7-4 PWM Return to FET PC Boards (J6-4) J7-5...
  • Page 63 J9-1 36 VAC from Logic PC Board (J4-1) J9-2 36 VAC from Logic PC Board (J4-2) J9-3 36 VAC from Logic PC Board (J4-3) J9-4 36 VAC from Logic PC Board (J4-4) J9-5 Return from Logic PC Board (J4-5) J9-6 36 VAC from Logic PC Board (J4-6) J9-7 Return from Logic PC Board (J4-7)

  • Page 64: Appendix Vi: Pilot Output Pc Board Layout

    APPENDIX VI: PILOT OUTPUT PC BOARD LAYOUT CGND A-01389 Pilot Output PC Board Signals J12-1 Torch Switch Filter in from J22-3 Torch Control J12-2 Not Used J12-3 Torch Switch Filter Return from J22-4 Torch Control J12-4 Not Used J12-5 Pilot Return Shield to J22-1 Torch Control J12-6 Torch Switch Shield to J22-2 Torch Control J12-7...
  • Page 65 CGND Chassis Gnd PS(-) (Stud) from Output Inductor L1 to CD Xfmr PS(-) C4 Rtn for Pilot Voltage Twisted with Pilot RTN to E23 PS(+) to E18 Upper Fet Module PS(+) to E18 Upper Fet Module From E22 to PCR Pin 2 From Pilot Choke to E20 C4 Rtn for Pilot Voltage Twisted with Pilot RTN from E8 Pilot RTN from Standoff on bulk head and Torch Cable...

  • Page 66: Appendix Vii: Cd Pc Board Layout

    APPENDIX VII: CD PC BOARD LAYOUT A-01208 CD PC Board Signals J11-1 36 VAC from Logic PC Board (J5-1) J11-2 Return from Logic PC Board (J5-2) J11-3 36 VAC from Logic PC Board (J5-3) J11-4 CD Enable Signal from Logic PC Board (J5-4) J11-5 Return for CD Enable Signal from Logic PC Board (J5-5) J11-6...

  • Page 67: Appendix Viii: Input Pc Board Layout

    APPENDIX VIII: INPUT PC BOARD LAYOUT Component Side Of PC Board Solder Side Of PC Board A-01390 CGND Input PC Board Signals J16-1 Gate Drive Relay Rtn from Logic Board J10-1 J16-2 Gate Drive Relay Pos from Logic Board J10-2 J16-3 Not used J16-4...

  • Page 68: Appendix Ix: Fet Pc Board Layout

    APPENDIX IX: FET PC BOARD LAYOUT Component Side Of PC Board - OUTPUT XFMR SEC MAIN XFMR PRI MAIN XFMR PRI MAIN XFMR SEC + OUTPUT A-01387 Solder Side Of PC Board APPENDIX Manual 0-2587...
  • Page 69 FET PC Board Signals (Upper and Lower Assemblies) J6-1 +12V from the Gate Drive Board upper J7-1 Lower J8-1 J6-2 +12V RTN from the Gate Drive Board upper J7-2 Lower J8-2 J6-3 Pwm Output from the Gate Drive Board upper J7-3 Lower J8-3 J6-4 Pwn Output RTN J6-2 from the Gate Drive Board upper J7-4 Lower J8-4 J6-5...

  • Page 70: Appendix X: Capacitor Pc Board Layout

    APPENDIX X: CAPACITOR PC BOARD LAYOUT A-01386 Capacitor PC Board Signals Positve Rail to FET Board Positve Rail to FET Board Negative Rail to FET Board Negative Rail to FET Board Positive Input from Input Board (+) SCR Cathode Negative Input from Input Board (-) Rectifier (-) APPENDIX Manual 0-2587...

  • Page 71: Appendix Xi: 36Vac Circuit Diagram

    APPENDIX XI: 36VAC CIRCUIT DIAGRAM CD PC Board Logic PC 12VDC Board Circuit 36 VAC Voltage Check Circuit Auxiliary (IN) 36 VAC Transformer Outputs (IN) 115 VAC Gate Drive PC Board J3 3 A-01344 ON/OFF Switch Manual 0-2587 APPENDIX...

  • Page 72: Appendix Xii: System Schematic

    APPENDIX XII: SYSTEM SCHEMATIC A-01370 APPENDIX Manual 0-2587...
  • Page 73 11/23 EC 8055 A-01370 Manual 0-2587 APPENDIX...

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