Summary of Contents for Thermal Dynamics Pak Master 75XL Plus
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PLASMA CUTTING POWER SUPPLY ® Pak Master 75XL™ Plus A-02464 Service Manual September 15, 2003 Manual No. 0-2747...
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Manufacturer assumes no liability for its use. Plasma Cutting Power Supply Pak Master ® 75XL Plus Service Manual Number 0-2747 Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.com Copyright 1999 by Thermal Dynamics Corporation All rights reserved.
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ....................1-1 1.01 Notes, Cautions and Warnings ..............1-1 1.02 Important Safety Precautions ............... 1-1 1.03 Publications ....................1-2 1.04 Note, Attention et Avertissement ..............1-3 1.05 Precautions De Securite Importantes ............1-3 1.06 Documents De Reference ................
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TABLE OF CONTENTS (continued) SECTION 6: REPLACEMENT PARTS ....................6-1 6.01 Introduction ....................6-1 6.02 Ordering Information ................... 6-1 6.03 Major External Replacement Parts .............. 6-2 6.04 Access Panel Replacement Parts ............... 6-3 6.05 Front Panel Replacement Parts ..............6-4 6.06 Left Side Internal Component Replacement Parts ........
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.
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding PLASMA ARC RAYS circuit. • Repair or replace all worn or damaged parts. Plasma Arc Rays can injure your eyes and burn your skin. •...
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE ATTENTION OF CUTTING AND WELDING PROCESSES, obtain- able from American National Standards Institute, 1430 Broadway, New York, NY 10018 Toute procédure pouvant résulter l’endommagement du matériel en cas de non- 7. AWS Standard A6.0, WELDING AND CUTTING CON- respect de la procédure en question.
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• Eloignez toute fumée et gaz de votre zone de respira- • Ne touchez jamais une pièce “sous tension” ou “vive”; tion. Gardez votre tête hors de la plume de fumée portez des gants et des vêtements secs. Isolez-vous provenant du chalumeau. de la pièce de travail ou des autres parties du circuit de soudage.
ultra-violets très forts. Ces rayons d’arc nuiront à vos 1.06 Documents De Reference yeux et brûleront votre peau si vous ne vous protégez pas correctement. Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples •...
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9. Norme 70 de la NFPA, CODE ELECTRIQUE NA- TIONAL, disponible auprès de la National Fire Pro- tection Association, Batterymarch Park, Quincy, MA 02269 10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 11.
Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.
None Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer.
C. Customer/Operator Responsibilities It is the customer/operator's responsibility to maintain the equipment and peripheral Accessories provided by Thermal Dynamics in good operating order in accordance with the procedures outlined in the Operating Manual, and to protect the equipment from accidental or mali- cious damage.
SECTION 3: 3.03 Specifications/Design Features DESCRIPTION A. Power Supply Technical Specifications The following specifications apply to the Power Supply only: 3.01 Scope 1. Front Panel Controls The purpose of the information in this section is: ON/OFF Switch, RUN/SET/LATCH Switch and •...
9. Weight D. Multi-Purpose Cart 64 lbs (29 kg) w/work lead Rugged steel cart on easy-rolling rear wheels and front-mounted swivel casters. Provides maximum 71 lbs (32 kg) w/work lead and 25' Torch & Lead mobility for the power supply and can also serve as a display cart.
Handle torch leads with care and protect them from Section 4: damage. TROUBLESHOOTING A. Piloting Piloting is harder on parts life than actual cutting be- 4.01 Introduction cause the pilot arc is directed from the electrode to the tip rather than to a workpiece. Whenever possible, This section provides service diagnostics for the Pak avoid excessive pilot arc time to improve parts life.
Manual requires Power Supply disassembly and live mea- surements. It is helpful for solving many of the common b. Torch standoff too high from workpiece problems that can arise with the Pak Master 75XL PLUS Power Supply. c. Worn torch parts If major complex subassemblies are faulty, the faulty sub- d.
C. How to use the Troubleshooting Guide A. Initial Setup Conditions The following information is a guide to help the Service 1. Connect gas supply to rear of Power Supply. Technician determine the most likely causes for various 2. Turn on gas supply and adjust Power Supply Gas symptoms.
2. Single phase jumper wire installed incorrectly C. Pilot Arc Test a. Refer to Operating Manual 0-2746, Section 3.07 1. Activate the torch (press torch switch on the and check jumper wire installation. handle, START signal from CNC or press the torch switch on the Remote Pendant) and note the fol- 3.
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10. Faulty ON/OFF switch (refer to Appendix 10, 36 V AC 4. Faulty RUN/SET/LATCH switch Circuit Diagram) a. Check continuity. Measure for 36 VAC on the Logic/Gate PC Board 5. Faulty gas solenoid circuit between J3-2 to J3-4. a. Test gas solenoid circuit per Section 4.09-G; re- a.
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5. Faulty Wiring or Logic/Gate PC Board Check for DC voltage from Logic/Gate PC Board Pilot Output PC Board J2-13 to TP1 (GND) • If less than a volt, replace Logic/Gate PC Board TP1 (GND) A-01399 Pin 3 Pin 1 A-02546 Logic/Gate PC Board G.
C. No arc in torch; Gas flows; AC indicator ON; 4.07 Pilot Arc Problems TEMP indicator off; GAS and DC indicators ON; No arc at spark gap on CD PC Board; CD enable Locate your symptom below: indicator (D2) ON A.
5. Faulty torch 4.08 Main Arc Problems a. Check continuity per appropriate Torch Instruc- Locate your symptom below: tion Manual. A. Main cutting arc will not start. 6. Faulty connection of wire #16 or #17 to Pilot Output PC Board 1.
2. Faulty PCR Relay 1. Remove the screws which secure the left side panel (viewed from front of unit) to the frame assembly. a. With power off, measure for continuity between wires #12 and #14. If continuity is found, re- place PCR.
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D. Input PC Board Test Check Input PC Board for shorted input diode. A-00307 0.75 Solder Side of PC Board Forward Bias Diode Conducting Diode Test Symbol VR COM Anode Cathode Testing Diode Forward Bias 6. Reverse the meter leads across the diode for reverse Input PC Board bias testing (refer to following figure).
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If Input Bridge Diode is shorted, make the following F. Temperature Circuit Test checks with an ohmmeter at the Main Contactor: Test the temperature circuit per the following: 1. Place the front panel ON/OFF switch to the OFF M e t e r (+ ) M e t e r (-) I n d ica t io n position.
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12. Check for short on Connector (harness end) be- H. Pilot Arc Circuit tween J2-15 & 16. Check across E23 to E24 at the Pilot Output PC Board. If shorted, replace TS1. There should be a diode drop across E23 to E24 in one direction and an open in the other.
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CD PC Board A-01202 Logic/Gate PC Board A-02550 1. No DC Output An open circuit voltage of approximately 280 to 325 vdc (depending on input power selected) is produced b. Connect a jumper between TP1 and TP8 of the when switching transistors in the FET/Heatsink As- Logic/Gate PC Board.
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e. If voltage is okay, check torch & leads. If volt- 3. MOSFET Resistance Checks age is low, disconnect wire from E24 on Pilot The Power Supply contains two identical FET/Heat- Output Board and recheck steps c-d. If volt- sink Assemblies. On each assembly there are two age is still low, disconnect wires 11-12 (from MOSFET devices that must be checked.
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Place the meter (+) lead on gate lead of Q6 and 5. FET Output Rectifier Check meter (-) lead on source lead of Q6. The meter Use a digital meter, diode or ohms function, to check should indicate approximately 2.5K ohms. the forward and reverse bias of the output rectifiers Place the meter (+) lead on drain lead of Q6 and on the FET/Heatsink Assemblies as follows:...
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Place the meter (+) lead on E18 and the meter (-) lead on the heatsink of the FET/Heatsink Assem- bly to check the output rectifier resistance to ground. The meter should indicate >1 meg ohms. Replace the FET/Heatsink Assemblies if any of the above tests are open or shorted.
Connect the equipment primary cable ground to SECTION 5: the same electrical ground as the wrist strap. REPLACEMENT Open the equipment enclosure (see instruction manual for the appropriate equipment) and remove PROCEDURES the failed PC Board. Carefully open the ESD protective bag and remove 5.01 Introduction the replacement PC Board.
C. Right Side Panel Replacement 5.04 Major External Parts Replacement Remove the Lifting Handle per paragraph 'A' above. Unlock the latch for the Access Panel. Refer to Section 6 for parts list and overall detailed draw- ing. Using a Phillips head screwdriver remove the two screws and loosen the three bottom screws which A.
B. ON/OFF Switch Replacement Remove the two nuts and washers securing the Ac- cess Panel to the Right Side Panel. Unlatch the Access Panel to gain access to the rear Install the replacement Access Panel by reversing of the ON/OFF Switch. the above procedure.
d. On the right side remove the two screws secur- C. Input PC Board Assembly Replacement ing the Pilot Panel to the Base/Front Panel As- Follow the Anti-Static Handling Procedures in Section 5.02. sembly. Remove the Left Side Panel per Section 5.04-B. e.
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Install the replacement Input Diode Bridge Assem- bly and new Thermal Pad by reversing the above Connection Description procedure (see Note). Main Transformer (Primary) NOTE Main Transformer (Primary) The two nuts removed in Step 3 must be torqued to Main Transformer (Secondary) 35 in-lbs when reinstalled.
B. Optional Single Stage Air Line Filter 5.08 Rear Panel Parts Replacement Element Replacement Refer to Section 6 for parts list and detailed drawing, and This part is an option; it may not be installed on all units. replacement parts catalog numbers. NOTE A.
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C. Optional Two Stage Air Line Filter D. Pressure Switch Replacement Replacement Remove power from power supply. This part is an option: it may not be installed on all units. Shut off air supply and bleed down system. Remove power from power supply. 3.
Remove the four screws securing the Air Line Regu- Disconnect all the wiring connections to the Pilot/ lator Bracket to the Rear Panel. Output PC Board Assembly. Pull the bracket from the unit. Remove the four screws and washers securing the PC Board to the standoffs.
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D. Main Transformer Assembly Replacement F. Auxiliary Transformer Assembly Replacement Remove the Left Side Panel per Section 5.04-B. Remove the Left Side Panel per Section 5.04-B. Remove the Right Side Panel per Section 5.04-C. Remove the Right Side Panel per Section 5.04-C. Remove the following terminal connections from the two FET/Heatsink Assemblies noting the loca- Disconnect the white wire single pin connector...
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G. Bulkhead Adapter Replacement Remove the Right Side Panel per Section 5.04-C. Remove Torch connection at the Bulkhead Adapter. A-02562 Tube Fitting Bracket Bulkhead Adapter Disconnect the gas tube from the fitting at the end of the Bulkhead Adapter. Remove the fitting. 5.
SECTION 6: REPLACEMENT PARTS 6.01 Introduction A. Parts Breakdown The Parts Lists provide a breakdown of all replaceable components. The Parts Lists are arranged as follows: Section 6.03 Major External Replacement Parts Section 6.04 Access Panel Replacement Parts Section 6.05 Front Panel Replacement Parts Section 6.06 Left Side Internal Component Replace- ment Parts Section 6.07 Rear Panel Replacement Parts...
6.03 Major External Replacement Parts Item # Description Catalog # Tube, Lifting Handle,1.125 OD,11.85 Lg 9-7505 Mount, Lifting Handle 9-7506 Cover, Left Side Includes: 9-8001 Cover Left Side Label, Warning, English Cover, Right Side Includes: 9-8016 Cover Right Side Overlay, RH Side Panel Labels Label, Warning, French Leads Wrap Includes:...
6.08 Right Side Internal Component Replacement Parts Item # Description Catalog # Bulkhead Adapter, O2B - 1/8 NPT 9-4045 9/16-18 Jam Nut, Brass 8-2149 Heatsink, Input Bridge (Shown With Pad) See Note 1 Chassis, Center See Note 1 Panel, Pilot Ass’y Mounting See Note 1 Brkt, Bulkhead Mounting See Note 1...
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A-02567 HARDWARE #10-32 Regular Nylon Lock Nut #10-32 x 2" PPH HDMS #10-32 x 0.5" PPH Sw ageform Stl Zn Screw 1/4-20 x 3" Screw , Soc HD #6-32 x 3 1/2" THD Screw #10-32 x 3/4" PPH Sw ag Screw #6-32x3/8 PPH STL ZN Screw Rubber Feet NOTE: Illustration may vary slightly...
APPENDIX 1: INPUT WIRING REQUIREMENTS Input P ower Input Current S uggested S izes (See Notes) V oltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps) W ire (AW G) W ire (Canada) (V olts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph 3-Ph...
APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIAGRAM) LATCH ACTION ACTION ACTION ACTION ON/OFF switch Close external RUN/SET/LATCH RUN/SET/LATCH switch to ON. disconnect switch. switch to RUN. to SET. RESULT RESULT RESULT RESULT AC indicator blinks for 8 Power to system. Gas flow stops.
APPENDIX 3: POT/LED PC BOARD LAYOUT A-01206 Pot/LED PC Board Signals J14-1 +10 vdc from Logic/Gate/Gate PC Board (J3-7) J14-2 Current Control to Logic/Gate PC Board (J3-8) J14-3 Return for Current Control from Logic/Gate PC Board (J3-9) J14-4 18VDC Unregulated from Logic/Gate PC Board (J3-10) J14-5 Active Low Signal for AC OK Indicator to Logic/Gate PC Board (J3-11) J14-6...
APPENDIX 4: LOGIC/GATE PC BOARD LAYOUT TP18 TP24 TP23 TP21 TP25 A-02528 Logic/Gate PC Board TP22 TP26 TP20 J3-5 Logic LowFrom RUN/SET/LATCH Switch Logic/Gate PC Board Signals on Front Panel (RUN) J3-6 PCB Common J1-1 36 VAC from Auxiliary Transformer J3-7 +10 vdc to Front Panel Current Control Pot J14-1 J1-2...
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J3-1 36 VAC to ON/OFF Switch J7-1 +12VDC J3-2 36 VAC from ON/OFF Switch to Logic/Gate PC Board J7-2 J3-3 36 VAC to ON/OFF Switch J7-3 J3-4 36 VAC from ON/OFF Switch to Logic/Gate PC Board J7-4 J3-5 Logic Low - From RUN/SET/LATCH Switch on Front Panel (RUN) J7-5 PRI Current Signal J3-6...
APPENDIX 5: 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...
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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...
APPENDIX 6: CD PC BOARD LAYOUT J11-1 J11-3 J11-4 J11-5 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...
APPENDIX 7: INPUT PC BOARD LAYOUT 2-position connector Solder Side of PC Board Component Side of PC Board Input PC Board A-02551 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...
APPENDIX 9: CAPACITOR PC BOARD LAYOUT E13B E12B E12A A-02633 E13C E12C Capacitor PC Board Signals Positive Rail to FET Board E12A Positive Rail to FET Board E12B Positive Rail to FET Board E12C Positive Rail to FET Board Negative Rail to FET Board E13A Negative Rail to FET Board E13B...
APPENDIX 11: MAINTENANCE SCHEDULE This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the parts listed and those checks need not be performed. NOTE The actual frequency of maintenance may need to be adjusted according to the operating environment. Daily Operational Checks or Every Six Cutting Hours: Check torch consumable parts, replace if damaged or worn.
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