™
150XL
®
PAK MASTER
PLASMA CUTTING SYSTEM
Service Manual
Rev. AA.01
Operating Features:
Date: April 27, 2007
Manual # 0-2697
460
V
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before
installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.
Plasma Cutting System
Pak Master® 150XL
Service Manual Number 0-2697
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 1999, 2007 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
any
this
any
publisher does not assume and hereby disclaims any liability to
party for any loss or damage caused by any error or omission in
Manual, whether such error results from negligence, accident, or
other cause.
Printed in the United States of America
Publication Date: April 27, 2007
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date: ___________________________________
Power Supply Serial #: ___________________________________
Torch Serial #: ___________________________________
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ................................................................................................. 1-1
1.01
1.02
1.03
1.04
1.05
1.06
1.07
1.08
Notes, Cautions and Warnings .....................................................................
Important Safety Precautions ........................................................................
Publications ..................................................................................................
Note, Attention et Avertissement ...................................................................
Precautions De Securite Importantes ............................................................
Documents De Reference .............................................................................
Declaration of Conformity ..............................................................................
Statement of Warranty ..................................................................................
1-1
1-1
1-2
1-3
1-3
1-5
1-7
1-8
SECTION 2:
INTRODUCTION ................................................................................................................ 2-1
2.01 Scope Of Manual .......................................................................................... 2-1
2.02 General Service Philosophy .......................................................................... 2-1
2.03 Service Responsibilities ................................................................................ 2-1
SECTION 3:
DESCRIPTION ................................................................................................................... 3-1
3.01
3.02
3.03
3.04
3.05
Scope of Manual ...........................................................................................
Power Supply General Description ................................................................
Specifications/Design Features .....................................................................
Power Supply Options and Accessories .......................................................
Theory Of Operation ......................................................................................
3-1
3-1
3-2
3-3
3-4
SECTION 4:
SERVICE .......................................................................................................................... 4-1
4.01
4.02
4.03
4.04
4.05
4.06
4.07
4.08
4.09
4.10
Introduction ................................................................................................... 4-1
Periodic Inspection & Procedures ................................................................. 4-1
System Theory ............................................................................................. 4-2
Common Operating Problems ....................................................................... 4-4
Troubleshooting Guide - General Information ................................................. 4-5
Circuit Fault Isolation .................................................................................... 4-6
Main Input and Internal Power Problems ....................................................... 4-7
Pilot Arc Problems ........................................................................................ 4-9
Main Cutting Arc Problems .......................................................................... 4-11
Test Procedures ........................................................................................... 4-12
SECTION 5:
REPLACEMENT PROCEDURES ...................................................................................... 5-1
5.01
5.02
5.03
5.04
5.05
5.06
5.07
5.08
5.09
Introduction ................................................................................................... 5-1
Anti-Static Handling Procedures ................................................................... 5-1
Parts Replacement - General Information ...................................................... 5-2
Major External Parts Replacement ............................................................... 5-2
Access Panel Parts Replacement ................................................................ 5-3
Left Side Center Chassis Parts Replacement ............................................... 5-5
Right Side Center Chassis Parts Replacement ............................................. 5-7
Base Parts Replacement ............................................................................. 5-13
Rear Panel Parts Replacement .................................................................... 5-16
TABLE OF CONTENTS (continued)
SECTION 6:
PARTS LISTS .................................................................................................................... 6-1
6.01 Introduction ................................................................................................... 6-1
6.02 Ordering Information ...................................................................................... 6-1
6.03 Major External Replacement Parts ............................................................... 6-2
6.04 Access Panel Replacement Parts ................................................................ 6-3
6.05 Left Side Center Chassis Replacement Parts ............................................... 6-4
6.06 Right Side Center Chassis Replacement Parts ............................................ 6-6
6.07 Base Replacement Parts ............................................................................. 6-8
6.08 Rear Panel Replacement Parts ................................................................... 6-10
6.09 Options and Accessories ............................................................................ 6-12
APPENDIX 1: INPUT WIRING REQUIREMENTS ....................................................................... A-1
APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ............................................ A-2
APPENDIX 3: POT/LED PC BOARD LAYOUT .......................................................................... A-3
APPENDIX 4: LOGIC PC BOARD LAYOUT ............................................................................... A-4
APPENDIX 5: GATE DRIVE PC BOARD LAYOUT ..................................................................... A-6
APPENDIX 6: PILOT/OUTPUT PC BOARD LAYOUT AND
WIRING CONNECTION DIAGRAM .................................................................................... A-8
APPENDIX 7: CD PC BOARD LAYOUT .................................................................................. A-10
APPENDIX 8: INPUT PC BOARD LAYOUT ............................................................................. A-11
APPENDIX 9: FET PC BOARD LAYOUT ................................................................................. A-12
APPENDIX 10: CAPACITOR PC BOARD LAYOUT .................................................................. A-14
APPENDIX 11: CURRENT SENSOR PC BOARD LAYOUT ..................................................... A-15
APPENDIX 12: 36VAC CIRCUIT DIAGRAM ............................................................................. A-16
APPENDIX 13: RECOMMENDED ROUTINE MAINTENANCE SCHEDULE
FOR LIQUID COOLED PLASMA CUTTING SYSTEMS .................................................... A-17
APPENDIX 14: SYSTEM SCHEMATIC (Unit Rev AU or Earlier) ............................................... A-18
APPENDIX 15: SYSTEM SCHEMATIC (Unit Rev AV - AY) ....................................................... A-20
APPENDIX 16: SYSTEM SCHEMATIC (Unit Rev AZ or Later) .................................................. A-22
SECTION 1:
GENERAL INFORMATION
GASES AND FUMES
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.
Keep your head out of the welding fume plume.
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
NOTE
• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different processes. You must
be very careful when cutting or welding any metals which may contain one or more of the following:
An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
Antimony
Arsenic
Barium
Beryllium
Cadmium
A procedure which, if not properly followed, may
cause damage to the equipment.
Chromium
Cobalt
Copper
Lead
Manganese
Mercury
Nickel
Selenium
Silver
Vanadium
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the information regarding the kind and amount of fumes
and gases that may be dangerous to your health.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.
1.02 Important Safety Precautions
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
WARNINGS
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEALTH.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth defects and, in some cases, cancer. (California Health
& Safety Code Sec. 25249.5 et seq.)
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health
equipment to determine whether a hazard exists.
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the operator or others in the workplace.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any
questions.
Manual 0-2697
• Never touch any parts that are electrically “live”
or “hot.”
1-1
GENERAL INFORMATION
• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit.
PLASMA ARC RAYS
• Repair or replace all worn or damaged parts.
Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyes and burn your skin if you are not properly protected.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publications.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Disconnect power source before performing any
service or repairs.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Read and follow all the instructions in the Operating Manual.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
FIRE AND EXPLOSION
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
• Be sure there is no combustible or flammable material in the workplace. Any material that cannot
be removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have
held combustibles.
Minimum Protective
Shade No.
Suggested
Shade No.
Less Than 300*
8
9
300 - 400*
9
12
400 - 800*
10
14
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters
may be used when the arc is hidden by the workpiece.
• Provide a fire watch when working in an area where
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will
cause an explosion.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402
NOISE
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent permanent loss of hearing.
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable
from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others
in the workplace.
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual.
GENERAL INFORMATION
Arc Current
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New
York, NY 10018
1-2
Manual 0-2697
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de nonrespect de la procédure en question.
7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
AVERTISSEMENT
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
1.05 Precautions De Securite
Importantes
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous
les avertissements, toutes les précautions de sécurité
et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votre distributeur
local si vous avez des questions.
1.04 Note, Attention et
Avertissement
Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des
informations à caractère important. Ces mises en relief
sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
Manual 0-2697
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.
1-3
GENERAL INFORMATION
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en air
si l’aération fournie ne permet pas d’éliminer la fumée
et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un ou
plusieurs des éléments suivants:
antimoine
argent
arsenic
baryum
béryllium
cadmium
chrome
cobalt
cuivre
manganèse
mercure
nickel
plomb
sélénium
vanadium
• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des gaz
pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 5.
• Ne touchez jamais une pièce “sous tension” ou “vive”;
portez des gants et des vêtements secs. Isolez-vous
de la pièce de travail ou des autres parties du circuit
de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la page
5, article 9.)
• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel de
consignes.
INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent résulter des scories
chaudes, des étincelles ou de l’arc de plasma. Le procédé
à l’arc de plasma produit du métal, des étincelles, des
scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées
inflammables.
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.
• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail. Protégez
toute telle matière qu’il est impossible de retirer de la
zone de travail.
• N’utilisez pas le chalumeau au jet de plasma dans une
zone où se trouvent des matières ou des gaz combustibles ou explosifs.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.
• Ce produit, dans le procéder de soudage et de coupe,
produit de la fumée ou des gaz pouvant contenir des
éléments reconnu dans L’état de la Californie, qui
peuvent causer des défauts de naissance et le cancer.
(La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)
• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail dans
une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler sous
les pièces de travail en aluminium lorsqu’elles sont
coupées sous l’eau ou sur une table d’eau. NE PAS
couper les alliages en aluminium sous l’eau ou sur
une table d’eau à moins que le gas hydrogène peut
s’échapper ou se dissiper. Le gas hydrogène accumulé
explosera si enflammé.
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’énergie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
GENERAL INFORMATION
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser
vos yeux et brûler votre peau. Le procédé à l’arc de
plasma produit une lumière infra-rouge et des rayons
1-4
Manual 0-2697
ultra-violets très forts. Ces rayons d’arc nuiront à vos
yeux et brûleront votre peau si vous ne vous protégez
pas correctement.
• Pour protéger vos yeux, portez toujours un casque ou
un écran de soudeur. Portez toujours des lunettes de
sécurité munies de parois latérales ou des lunettes de
protection ou une autre sorte de protection oculaire.
• Portez des gants de soudeur et un vêtement protecteur
approprié pour protéger votre peau contre les
étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection
en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant des
cabines ou des écrans de protection.
• Utilisez la nuance de lentille qui est suggèrée dans le
recommendation qui suivent ANSI/ASC Z49.1:
Courant Arc
Nuance Minimum
Protective Numéro
Nuance Suggerée
Numéro
Moins de 300*
8
9
300 - 400*
9
12
400 - 800*
10
14
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. Vous dú4ez vous protéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres personnes
se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer que
les décibels (le bruit) ne dépassent pas les niveaux
sûrs.
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
Manual 0-2697
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE
PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de l’Institut
Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York,
NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES
LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET
DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York,
NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS AYANT RENFERMÉ DES PRODUITS
COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269
1-5
GENERAL INFORMATION
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de la
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA
SÉCURITÉ DU SOUDAGE, disponible auprès de
l’Association Nationale de Fournitures de Soudage
(National Welding Supply Association), 1900 Arch
Street, Philadelphia, PA 19103
14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRÉPARATION À LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT
RENFERMÉ
DES
PRODUITS
DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION
1-6
Manual 0-2697
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address:
82 Benning Street
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage
Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National
legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive"
(European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture
a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and
associated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and
related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing
process to ensure the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence
in our area of manufacture.
Manufacturers responsible representative: Steve Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
Manual 0-2697
1-7
GENERAL INFORMATION
1.08 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in
workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal
products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but not
limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service
interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or
anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of
any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise,
shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar
and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from
date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).
The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).
Parts
PAK Units, Power Supplies
XL Plus &
CutMaster Series
Parts
Cougar/Drag-Gun
Parts
All Others
Labor
Main Power Magnetics
3 Years
1 Year
2 Years
1 Year
Original Main Power Rectifier
3 Years
1 Year
2 Years
1 Year
Control PC Board
3 Years
1 Year
2 Years
1 Year
All Other Circuits And Components Including,
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
Consoles, Control Equipment, Heat
Exchanges, And Accessory Equipment
1 Year
Torch And Leads
Maximizer 300 Torch
SureLok Torches
1 Year
All Other Torches
180 Days
180 Days
180 Days
180 Days
90 Days
90 Days
90 Days
None
Repair/Replacement Parts
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges
to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the
customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective: November 15, 2001
GENERAL INFORMATION
1-8
Manual 0-2697
SECTION 2:
INTRODUCTION
2.01 Scope Of Manual
This Manual provides Service Instructions for Thermal
Dynamics PAK Master® 150XL Plasma Power Supply.
Refer to Operating Manual supplied with the Power Supply for individual operating procedures. Information in
this edition is therefore particularly applicable to the
Troubleshooting and Repair of the equipment, and is intended for use by properly trained Service Technicians
familiar with this equipment.
2.03 Service Responsibilities
The Service Technician should be familiar with the equipment and its capabilities and should be prepared to recommend arrangements of components which will provide the most efficient layout, utilizing the equipment to
its best possible advantage.
Maintenance work should be accomplished in a timely
manner. If problems are encountered, or the equipment
does not function as specified, contact Technical Services
Department at West Lebanon for assistance.
Read this manual and the Operating Manual thoroughly.
A complete understanding of the capabilities and functions of the equipment will assure obtaining the performance for which it was designed.
2.02 General Service Philosophy
Several key points are essential to properly support the
application and operation of this equipment.
A. Application
The equipment should satisfy the customer’s requirements as supplied and as described in Section 3 of this
manual. Be sure to confirm that the equipment is capable
of the application desired.
B. Modifications
No physical or electrical modifications other than selection of standard options and accessories are to be made
to this equipment.
C. Customer/Operator Responsibilities
It is the customer/operator's responsibility to maintain
the equipment and peripheral accessories provided by
Thermal Dynamics in good operating order in accordance
with the procedures outlined in the Operating Manual,
and to protect the equipment from accidental or malicious damage.
D. Repair Restrictions
The electronics consists of Printed Circuit Board Assemblies which must be carefully handled, and must be replaced as units. No replacement of printed circuit solder-mounted components is allowed except as noted in
this manual.
Printed Circuit Board Assemblies to be returned must be
properly packaged in protective material and returned
intact per normal procedures.
Manual 0-2697
2-1
INTRODUCTION
This Page Left Blank
INTRODUCTION
2-2
Manual 0-2697
SECTION 3:
DESCRIPTION
3.01 Scope of Manual
The information in this section has two purposes:
• To familiarize the service technician with the capabilities and limitations of the equipment,
• To provide an overall understanding which will allow the technician, in turn, to properly train
customer's operating personnel.
3.02 Power Supply General
Description
Power Supply is designed to cut most metals up to 1-1/2
inches (38 mm) using air, nitrogen, or argon/hydrogen
as the plasma gas. This system is also capable of satisfying many gouging applications. The Power Supply is
ideal for hand applications and can also be used in mechanized applications.
The Power Supply provides 120 amp maximum output
current and includes all control circuitry, electrical and
gas inputs and outputs, pilot circuitry, torch leads receptacle and a 20 ft (6.1 m) work cable with clamp.
The torch used with the Power Supply is available in the
following configurations:
Art # A-07844
Figure 3-1 Pak Master 150XL System
The Extra-CoolTM Coolant supplied with the Power Supply can be used in ambient temperatures down to 10° F
(-12° C). For lower temperatures, Ultra-CoolTM Coolant
should be used. This coolant can be used in areas where
the ambient temperature drops to -27° F (-33° C).
A. Typical System
A typical system configuration will contain the following:
• Power Supply
• 70° or 90° Hand Torch Head (PCH)
• 20 ft (6.1 m) Work Cable with Clamp
• 180° Machine Torch Head (PCM) with 1-3/8 inch
(34 mm) diameter Mounting Tube with Rack and
Pinion Assembly
Machine torch systems with unshielded leads include a
Remote Hand ON/OFF Pendant; machine torches with
shielded leads include a CNC Interface Cable.
• Torch with Leads (torch type and leads length as
ordered)
• Torch Spare Parts Kit
• CNC Interface Cable or Remote Pendant Control
(depending on type of torch leads ordered)
• Standard Thermal Arc Coolant - 3 gallons (11.4 liters)
NOTE
NOTES
The power supply can be ordered in various configurations with various options factory installed.
Refer to Section 3.04 for complete list of Power Supply Options and Accessories.
Refer to the supplied Torch Instruction Manual for
more information on the Torch.
Refer to Section 3.04 for list of Power Supply Options and Accessories.
B. Requirements to Complete System
To complete the system, the user needs to provide the
following:
• Primary Input Power Cable
• Gas Supplies
Manual 0-2697
3-1
DESCRIPTION
3.03 Specifications/Design
Features
Power Supply Duty Cycle
Ambient
Temperature
104° F
(40° C)
104° F
(40° C)
The following specifications apply to the Power Supply
only:
Duty Cycle
60%
100%
Current
120 Amps
n/a Amps
1. Front Panel Controls
DC Voltage
128 vdc
n/a vdc
A. Power Supply Specifications
• ON/OFF, RUN/SET and STANDARD/LATCH
Switch
7. Cut Capacity on Carbon Steel
• Output Current Control
• Genuine Cut Capacity: 1-1/2 inch (38 mm)
• Work Cable Connection
• Severance Cut: 1- 3/4 inch (44 mm)
• Torch Leads Connection
2. Front Panel LED Indicators
• Pierce Rating: 5/8 inch (15.9 mm)
8. Pilot Circuitry
Capacitive Discharge (CD), Pulsed DC
• AC
• TEMP
9. CNC Interface Signals
• GAS Pressure/Coolant Flow
• DC Output
3. Rear Panel
Start/Stop and OK-To-Move
10. Coolant Pressure
Internal Service Adjustable (Factory Only)
• Primary Input Power Cable Strain Relief
• Plasma Gas Supply Connection
130 psi (8.8 bar) at zero flow
• Plasma Gas Regulator/Filter Assembly with Gas
Pressure Gauge and Pressure Adjustment
120 - 125 psi (8.2 - 8.5 bar) at 0.6 gpm (2.3 lpm)
• Secondary Gas Supply Connection
11. Coolant Flow Rate
0.5 gpm (1.9 lpm) with 150 feet (45.7 m) of total torch
and torch leads at 70°F (21°C)
• Secondary Gas Regulator/Filter Assembly with Gas
Pressure Gauge and Pressure Adjustment
4. Input Power (see NOTES)
NOTE
The flow rate varies with lead length, torch configuration, ambient temperature, amperage level,
etc.
208/230/460 VAC (±10%), 50/60 Hz, Three-Phase
220/380-415 VAC (±10%), 50/60 Hz, Three-Phase
575 VAC (±10%), 50/60Hz, Three-Phase
12. Cooling Capacity
NOTES
4,000 to 10,000 BTU
Refer to Appendix 1 for suggested input wiring
size, current ratings and circuit protection requirements.
Units using 575 VAC input power require installation of Optional 575V Transformer Assembly.
NOTE
Maximum value based on “free flow” condition.
13. Coolant Reservoir Capacity
2 gallons (Use Thermal Arc® coolant only)
5. Output Power
Capable of handling a total of 150 feet (45.7 m) of
torch lead length
Continuously variable from 30 to 120 amps (±5%)
6. Duty Cycle (see NOTE)
14. Overall Dimensions
Height: 45-3/8 inches (1.2 m)
NOTE
Width: 24-1/2 in (0.6 m)
The duty cycle will be reduced if the primary input voltage (AC) is low or the DC voltage is higher
than shown in the chart.
DESCRIPTION
Depth: 35 inches (0.9 m)
3-2
Manual 0-2697
15. Weight
Power Supply with Torch: 275 lbs (125 kg)
3.04 Power Supply Options and
Accessories
Shipping Weight: 350 lbs (158.8 kg)
NOTE
16. Used With Torch
Refer to Section 6, Parts Lists, for part numbers
and ordering information.
• PCH-120 Hand Torch
• PCM-120 Machine Torch
B. Gas Regulator/Filter Assembly
Specifications
The following are accessories that are available for the
Power Supply:
A. Primary Input Power Cable
The following specifications apply to the Gas Regulator/
Filter Assembly only:
The following input power cables are available:
• 230VAC, (2AWG) 10 ft (3 m)
1. Gas Regulator Maximum Gauge Pressure
Plasma: 160 psi (11.3 bar)
• 460VAC, (6AWG) 10 ft (3 m)
B. Two Stage Air Line Filter
Secondary: 160 psi (11.3 bar)
An optional Two Stage Air Line Filter is available.
The filter will remove moisture and contaminants
from the air stream when using compressed air. The
filter is capable of filtering to at least 5 microns. The
filter assembly is pre-assembled at the factory and
need only be installed on the power supply.
2. Maximum Input Gas Pressure
125 psi (8.6 bar)
3. Filter
Coalescent type filter
C. High Pressure Regulators
C. Gas Requirements
High pressure regulators are available for air, nitrogen, and argon-hydrogen. The regulators are used
to set the proper pressure for the type of gas being
used.
1. Plasma
Gases: Compressed Air, Nitrogen, Argon/Hydrogen
Operating Pressure: 65 psi (4.5 bar)
D. 575V Transformer
Cold Flow:
This 575 VAC to 460 VAC Step-down Transformer
allows the Power Supply to operate on 575 VAC threephase input power.
Cutting: 50 - 78 scfh (23.6 - 36.8 lpm)
Gouging: 85 - 95 scfh (40.1 - 44.8 lpm)
E. CNC Interface Cable
CAUTION
NOTE
Accessory is for use with Shielded PCM Torch &
Leads.
Maximum input gas pressure must not exceed 125
psi (8.6 bar).
The CNC Interface Cable is available in two lengths:
25 ft (7.6 m) and 50 ft (15.2 m). The cable is used to
interface the Power Supply with an auxiliary control
device to provide OK-To-Move and ON/OFF signals.
2. Secondary
Gases: Compressed Air, Carbon Dioxide (C02), Nitrogen
Operating Pressure: 60 psi (4.1 bar)
F. Work Cable Kit
Cold Flow:
Power Supply is supplied with attached 20 ft (6.1 m)
work cable and clamp. Longer cables are available
as a user installed kit.
Cutting: 340 scfh (160.4 lpm)
Gouging: 235 scfh (110.9 lpm)
CAUTION
Maximum input gas pressure must not exceed 125
psi (8.6 bar).
Manual 0-2697
3-3
DESCRIPTION
G. Remote Pendant Control
E. RF Shielding
Machine torch systems using CNC Interface Cables are
shielded to minimize radio frequency (RF) interference
which results from the high frequency arc initiation. These
shielded systems are designed with features such as a
wire for establishing an earth ground and shielded torch
and control leads. The CNC control signals are filtered
on an internal PC Board.
NOTE
Accessory is for use with Unshielded PCM Torch
& Leads.
Control used to manually start and stop cutting operations from a location up to 20 ft. (6.1 m) from the
Plasma Power Supply.
F. Interlocks
3.05 Theory Of Operation
The system has several built-in interlocks to provide safe
and efficient operation. When an interlock shuts down
the system, the fault condition must be remedied and the
system recycled using the applicable control device.
A. Plasma Arc Cutting and Gouging
Plasma is a gas which is heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting process uses this plasma
gas to transfer an electric arc to a workpiece. The metal
to be cut is melted by the intense heat of the arc and then
blown away by the flow of gas.
1. Parts-In-Place (PIP) Interlock
With a simple change of torch parts, the system can also
be used for plasma arc gouging. Plasma arc gouging uses
the same process to remove material to a controlled depth
and width.
The Power Supply has a built-in parts-in-place interlock that prevents accidental torch starting
when torch parts are not properly installed. A flow
switch on the coolant return lead detects reduced
coolant flow caused by improper torch assembly.
If not satisfied, the switch interrupts power to the
tip and electrode.
2. Gas Pressure Interlock
B. Input and Output Power
The unit converts AC input power to DC power for the
main cutting arc. The negative output is connected to
the torch electrode through the negative torch lead, and
the positive output connects to the workpiece through
the work cable.
C. Pilot Arc
When the torch is activated there is a 2 second (service
adjustable) gas pre-flow, followed by an uninterrupted
pulsed DC pilot arc established between the electrode and
tip. The pilot arc is initiated by a momentary high frequency pulse from the Power Supply. The pilot creates a
path for the main arc to transfer to the work. When the
main arc is established, the pilot arc shuts off. The pilot
automatically restarts when the main arc stops, as long
as the torch remains activated.
A pressure switch acts as an interlock for the
plasma gas supply. If the plasma gas supply pressure falls below minimum requirements the pressure switch will open, shutting off the power to
the contactors, and the GAS indicator will go out.
When adequate plasma supply pressure is available the pressure switch will close, allowing power
to be resumed for cutting.
NOTE
There is no gas pressure interlock for secondary
gas.
D. Main Cutting Arc
The power supply converts the AC input power to DC
power for the main cutting arc. The negative output is
connected to the torch electrode through the negative
torch lead. The positive output is connected to the workpiece via the work cable and clamp connection.
DESCRIPTION
3-4
Manual 0-2697
SECTION 4:
SERVICE
WARNING
Do NOT blow air into the power supply during
cleaning; make sure to always blow air out of the
unit. Blowing air into the unit can cause metal
particles to interfere with sensitive electrical components and cause damage to the unit.
4.01 Introduction
This section provides service diagnostics for the Pak Master
150XL Power Supply, allowing the Technician to isolate any
faulty subassemblies. Refer to Section 5, Repairs & Replacement Procedures, for parts replacement instructions.
Under no circumstances are field repairs to be attempted on
Printed Circuit Boards or other subassemblies of this unit. Evidence of unauthorized repairs will void the factory warranty.
NOTE
The troubleshooting contained in this manual is
for the Power Supply only. Troubleshooting other
parts of the system is covered in the separate manuals for that product.
4.02 Periodic Inspection &
Procedures
While the side panels are off, inspect the wiring in the
unit. Look for any frayed wires or loose connections that
should be corrected.
D. Coolant Filter Assembly
The Coolant Filter Screen should be cleaned periodically.
To gain access to the Coolant Filter Assembly, remove the
right side panel when viewed from front of unit. Remove
the Filter Screen by unscrewing the filter holder from the
Coolant Filter Assembly. Clean the filter screen by rinsing with hot soapy water. Remove soap residue by rinsing with clean hot water. Be sure that all the soap has
been removed and the screen is dry of water before reinstalling in the Coolant Filter Assembly.
NOTE
Refer to Appendix 13 for a recommended maintenance schedule for water cooled plasma cutting systems.
This subsection describes inspection procedures which
should be performed at periodic intervals as required.
A. Physical Inspection
Filter
Check that all cable connections are secure.
B. Fan Motor and Pump Lubrication
The fan motor and pump in the power supply should
be oiled twice per year or once for each 100 hours of
operation. To oil the motor, remove one side panel
and add two or three drops of 20 SAE oil to the front
and rear oil holes on the motor.
Filter Holder
A-02152
NOTE
Some units may utilize a sealed motor design which
does not require lubrication.
Figure 4-1 Coolant Filter Assembly
C. Power Supply Cleaning
E. In-Line Coolant Filter Assembly
To clean the unit, open the enclosure and use a vacuum cleaner
to remove any accumulated dirt and dust. The unit should also
be wiped clean. If necessary, solvents that are recommended
for cleaning electrical apparatus may be used.
The In-line Coolant Filter Screen should be cleaned periodically. To gain access to the In-Line Coolant Filter Assembly
remove the right side panel (when viewed from the front of
unit). Remove the Filter Screen by unscrewing the Filter Holder
from the In-Line Coolant Filter Assembly. Clean the Filter Screen
by rinsing with hot soapy water. Remove soap residue by
Manual 0-2697
4-1
SERVICE
rinsing with clean hot water. Be sure that all the soap has been
removed and the screen is dry of water before reinstalling in the
In-Line Coolant Filter Assembly.
3. Carefully lower the hose out the right side of the Power
Supply and drain the coolant into an acceptable container.
CAUTION
Handle and dispose of the used coolant per recommended procedures.
Filter
Filter Holder
Coolant Filter
Assembly
Place hose in
bucket to drain
Coolant
Reservoir
A-02153
Coolant
Input Hose
Figure 4-2 In-Line Filter Assembly
F. Coolant Level and Conductivity
1. Coolant Level
A-03049
The coolant level should be checked every day at
the rear panel coolant gauge. If the coolant in the
reservoir is more than 2 inches (50 mm) from the
top of the reservoir then add Torch Coolant.
2. Coolant Conductivity
Figure 4-3 Draining Coolant From Reservoir
The coolant conductivity level should be checked
if the pilot doesn't start.
4. Reconnect the hose to the Coolant Filter Assembly.
Check the condition of the deionizer bag in the
reservoir basket, if the bag is yellowish brown
(straw color) replace the bag and coolant (see
NOTE).
5. Remove Coolant Reservoir lid and install new
coolant and deionizer bag.
6. Reinstall the right side panel.
NOTE
To accurately measure the coolant conductivity it
is recommended to use a Conductivity Sensor similar to Thermal Dynamics Model TDS-73 (Catalog
# 7-2844).
G. Draining and Replacing Coolant
4.03 System Theory
The Cutting System is designed for hand cutting and simple
mechanized operation using the torch control bulkhead as the
interface.
A. Logic PC Board Functions
Remove the old coolant from the Power Supply reservoir as
follows:
NOTE
Refer to Appendix 4 for Logic PC Board Layout.
1. Remove the right side panel from the Power Supply.
2. Disconnect the coolant input hose to the Coolant Filter Assembly.
SERVICE
4-2
Manual 0-2697
The Logic PC Board controls the timing and sequencing of
the system. It monitors the pressure, temperature, and
flow interlocks and controls the gas flow in run and set
modes by turning on the plasma and secondary solenoids.
The Logic PC Board also controls the power on the voltage selection and prepurge functions.
Logic PC Board
Indicator
After the ON/OFF switch is closed on the front panel, the
AC Indicator blinks and the GAS Indicator is on steady.
The AC Indicator blinks for approximately 8 seconds then
at that time it becomes steady and the inrush relay closes.
The GAS Indicator stays on for approximately 20 seconds
(prepurge function) then goes off and the gas stops flowing.
When the torch switch is pressed, D26 "start" Indicator
comes on, gas will flow for approximately 2 seconds before
DC is established (indicated on the front panel). During
this time D25 CD Enable will come on and sends a logic
signal to the CD Board which fires the spark gap and initiates the torch to pilot. D25 should go out immediately if
the pilot starts immediately.
When the torch is close to the workpiece, the cutting arc
"transfers" to the work. Also, if the tip touches the workpiece, the current is automatically folded back to approximately 35 amps to save the tip from being blown out.
The resulting current is sensed by the Current Sense PC
Board, resulting in the demand level changing from pilot
current to whatever the main current control is set at. During the "transfer" the CSR Indicator (D65) comes on and
the transfer enable signal goes low allowing the bottom
gate drive and FET modules to come up and start running.
Also at this time, D5 (located on the Pilot Output PC Board)
shuts off and at this time the main cutting arc is initiated. If
the torch is removed from the workpiece, the pilot arc will
automatically restart if the torch switch is still pressed.
Meaning
D26
Torch Switch Enable - When ON
(start) indicates torch switch is
pressed.
D25
CD Enable - Initiates spark gap on
CD PC Board. Indicator should
come ON then go OFF after a pilot
arc has been established.
D65
CSR - Indicates main cutting arc is
established.
D47
AC OK - When ON indicates that AC
Input voltage is okay.
D31
Drag - When ON indicates that the
torch tip is making contact with the
workpiece.
B. CD (Capacitive Discharge) PC Board
Functions
NOTE
Refer to Appendix 7 for CD PC Board Layout.
The CD PC Board functions are initiated by the CD
Enable signal from the Logic PC Board. The CD arc
starting circuit fires the spark gap producing the high
voltage spark which starts the DC pilot arc. When a
pilot arc is sensed by the Gate Drive Board, the PSR
signal shuts off the CD enable.
C. Gate Drive PC Board Functions
NOTE
Refer to Appendix 5 for Gate Drive PC Board Layout.
This board controls the amount of time the FETs are
turned on. This is done with a pulse width modulator (PWM) controlled by the demand signal from the
Logic PC Board (The longer the FETs are on, the more
output current). If a short develops, the primary
overcurrent will shut down the gate drive and not
allow the power supply to power up and run.
Manual 0-2697
4-3
SERVICE
The PSR signal senses any current in the secondary and
determines what the PWM should do for a pulse width. If
there is current in the secondary, the PSR signal will go
back to the Logic PC Board and shut off the CD Enable
signal.
4.04 Common Operating Problems
WARNINGS
Disconnect primary power at the source before
disassembling the power supply, torch, or torch
leads.
Gate Drive PC Boards
Indicator
D4
D20
Meaning
Frequently review the Important Safety Precautions in Section 1. Be sure the operator is equipped
with proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body comes
into contact with the workpiece while the torch is
activated.
Power Enable - When ON PWM
Enable received from the Logic
PC Board.
Reset - Normally ON, goes out
when torch switch is pressed.
Indicator will blink if primary overcurrent is detected when torch
switch is pressed.
CAUTION
Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.
D. Pilot/Output PC Board Functions
NOTE
Refer to Appendix 6 for Pilot/Output PC Board
Layout.
This board has an IGBT which is turned on by the
Logic Board for piloting. This allows the DC to flow
from the output (-) through the pilot return (tip) to a
Pilot Inductor and finally to the work. This path is
broken very quickly by the IGBT when the main cutting arc is initiated. This board also filters the torch
shield back to the torch (-) through the Capacitor.
Indicator
D5
Pilot PC Board
Meaning
NOTE
Handle torch leads with care and protect them from
damage.
A. Piloting
Piloting reduces parts life more 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.
B. Torch Standoff
IGBT is turned on from the logic signal
coming from the Logic Board PCR J5-6.
NOTE: This LED is on during piloting; it is
off during cutting.
E. Current Sense PC Board Functions
Improper standoff (the distance between the torch
tip and workpiece) can adversely affect tip life as well
as shield cup life. Standoff may also significantly affect the bevel angle. Reducing standoff generally results in a more square cut.
C. Edge Starting
NOTE
For edge starts, hold the torch perpendicular to the
workpiece with the front of the torch tip at the edge
of the workpiece, not touching, at the point where
the cut is to start. When starting at the edge of the
plate, do not pause at the edge and force the arc to
“reach” for the edge of the metal. Establish the cutting arc as quickly as possible.
Refer to Appendix 11 for Current Sense PC Board
Layout.
This board senses current in the work lead (approximately 3 amps). When this happens, it sends a signal back to the Logic Board. This in turn tells the
Logic to change demand levels from pilot current to
main cutting current.
D. Direction of Cut
The plasma gas stream swirls as it leaves the torch.
The purpose of the swirl is to maintain a smooth column of gas. The swirl effect results in one side of a
SERVICE
4-4
Manual 0-2697
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.
4. Short Torch Parts Life
a. Oil or moisture in air source
b. Exceeding system capability (material too thick)
E. Dross
When dross is present on carbon steel, it is commonly
referred to as either “high speed, slow speed, or top
dross”. Dross present on top of the plate is normally
caused by too great a torch to plate distance. "Top
dross" is normally very easy to remove and can often
be wiped off with a welding glove. "Slow speed
dross" is normally present on the bottom edge of the
plate. It can vary from a light to heavy bead, but
does not adhere tightly to the cut edge, and can be
easily scraped off. "High speed dross" usually forms
a narrow bead along the bottom of the cut edge and
is very difficult to remove. When cutting a troublesome steel, it is sometimes useful to reduce the cutting speed to produce "slow speed dross". Any resultant cleanup can be accomplished by scraping, not
grinding.
c. Excessive pilot arc time
d. Air flow too low (incorrect pressure)
e. Improperly assembled torch
f.
Incorrect torch parts for the operation
g. Non-Genuine Thermal Dynamics parts used
4.05 Troubleshooting Guide General Information
WARNING
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
power electronics measurement and troubleshooting techniques.
F. Common Cutting Faults
1. Insufficient Penetration
a. Cutting speed too fast
b. Torch tilted too much
A. Basic Troubleshooting
c. Metal too thick
For basic troubleshooting and parts replacement, refer to
Operating Manual. This manual should be your first resource for troubleshooting. If the problem cannot be remedied using the Operating Manual, refer to the advanced
troubleshooting in this Service Manual.
d. Worn torch parts
e. Cutting current too low
f. Drag cutting above 35 amps ("Tip Saver Circuit")
2. Main Arc Extinguishes
a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Cutting current too high
d. Work cable disconnected or bad connection
e. Worn torch parts
3. Excessive Dross Formation
a. Cutting speed too slow
B. Advanced Troubleshooting
This manual provides advanced troubleshooting and
parts replacement not covered in the basic troubleshooting section of the Operating Manual. In most cases, it
requires Power Supply disassembly and live measurements.
Troubleshooting and repair of this unit is a process which
should be undertaken only by those familiar with high
voltage high power electronic equipment.
If major complex subassemblies are faulty, the faulty subassembly must be returned for repair.
b. Torch standoff too high from workpiece
NOTE
c. Worn torch parts
Follow all instructions as listed and complete each
in the order presented.
d. Improper cutting current
e. Improper gas selection for cutting material
Manual 0-2697
4-5
SERVICE
Subsection 4.09 includes specific test procedures and LED status identification tables. The subsection is referenced by the
troubleshooting guide for the specific test to be performed.
The troubleshooting guide has six subsections as follows:
4.06 Circuit Fault Isolation
This section is used before troubleshooting to help isolate the
defective circuit, identify symptoms, and test the unit for proper
operation.
Section 4.06 - Circuit Fault Isolation
NOTE
Section 4.07 - Main Input and Internal Power Problems
Follow all instructions as listed and complete each
in the order presented.
Section 4.08 - Pilot Arc Problems
Section 4.09 - Main Arc Problems
Section 4.10 - Test Procedures
C. How to Use the Troubleshooting Guide
The following information is a guide to help the Service Technician determine the most likely causes for various symptoms.
This guide is set up in the following manner:
1. Perform operational check(s) on the equipment to isolate
problem to possible circuit(s) per Section 4.06, Circuit Fault
Isolation. Refer to the Appendix Pages for PC Board layouts, as necessary.
Follow the instructions as given to identify the possible
symptom(s) and the defective circuit. After repairs are
complete then run the following tests again to verify that
the unit is fully operational.
A. Initial Setup Conditions
Connect gas supply to rear of Power Supply.
Turn on gas supply and adjust the Plasma Gas Regulator
to 65 psi (4.5 bar) and the Secondary Gas Regulator to 60
psi (4.1 bar).
Set the Power Supply controls as follows:
2. Determine symptom and isolate to defective assembly using the following format:
ON/OFF switch to OFF
RUN/SET switch to SET
X. Symptom (Bold Type)
CURRENT control potentiometer to maximum
Any Special Instructions (Text Type)
STANDARD/LATCH switch to STANDARD (See
NOTE)
1. Cause (Italic Type)
a. Check/Remedy (Text Type)
NOTE
a. Locate your symptom in the appropriate sub-section.
b. Check the causes (easiest listed first) for the symptom.
c. Check the remedies listed for each cause.
3. Repair as needed being sure to verify that unit is fully operational after any repairs.
STANDARD/LATCH Switch was not installed on
revision AU or earlier Power Supplies.
B. Main Input and Internal Power Tests
Connect main AC power to the unit.
Set the Power Supply ON/OFF switch to ON and note
the following:
• AC indicator blinks for eight (8) seconds, then steady
ON
NOTES
Many signals are transferred between Printed Circuit Board Assemblies on Ribbon Cables. If these
cables become faulty they can then cause various
problems. Do not forget about these cables when
troubleshooting.
• Main Contactor energizes (clicks once) while AC Indicator is blinking
• Inrush Relay energizes (clicks once) after AC Indicator stops blinking
• TEMP Indicator OFF
While troubleshooting visually inspect the internal components for signs of overheating, fractures
and damage.
• GAS Indicator ON
• Gas flows
• Fans operate
• DC Indicator OFF
SERVICE
4-6
Manual 0-2697
Set the Power Supply RUN/SET switch to the RUN position
and note the following:
4.07 Main Input and Internal Power
Problems
• Gas Indicator goes OFF
NOTES
• Gas flow stops
The Input PC Board has a neon light on the upper
left hand corner. If AC power is present on L1, L2,
L3 of the Main Contactor, the light will be on.
NOTE
This unit has a 20 second pre-purge feature which
begins when the unit is turned ON. As long as the
RUN/SET Switch is in the SET position, the gas
will flow indefinitely. However, once the RUN/
SET Switch is placed in the RUN position, the gas
will stop flowing after approximately 20 seconds
(The 20 seconds begins from the time the unit is
turned on, not from when the unit was put in the
RUN position.)
Refer to the Appendix Pages for PC Board Layouts.
Locate your symptom below:
A. Main power line fuses blow as soon as main
disconnect is closed
1. Input power cable installed incorrectly
This completes the Main Input and Internal Power Tests.
If the unit functions as described above, and all correct
then proceed to the Pilot Arc Test below.
If the unit does not function as noted then note the symptom and proceed to Section 4.07, Main Input and Internal Power Problems.
a. Refer to Operating Manual, Section 3.07, Input
Power Cable Connections, and connect input
cable
B. Main power line fuses blow when unit is powered
on
1. Input Bridge Faulty
C. Pilot Arc Test
a. Test Input Bridge Rectifier per Section 4.10-D;
repair as necessary
Press the torch switch to establish a pilot arc and note the
following:
2. Faulty FET/Heatsink Assembly
• Gas flows
a. Check per Section 4.10-K; repair as necessary
• GAS indicator turns ON
3. Faulty Input PC Board
• After preflow delay DC indicator turns ON
• Pilot arc established
This completes the Pilot Arc Test. If the above are all correct then proceed to the Main Arc Test below.
If the above does not function as noted then note the
symptom and proceed to Section 4.08, Pilot Arc Problems.
a. Test Input PC Board per Section 4.10-D; repair
as necessary
C. AC indicator on front panel of power supply is
OFF
1. Front Panel ON/OFF switch in OFF position
D. Main Arc Test
a. Place switch to ON position
Press the Torch Switch to establish a pilot arc.
2. Main power disconnect not closed
Bring the torch to within 1/8"-3/8" (3.2 - 9.5 mm) of the
workpiece to establish the main cutting arc, and note the
following:
a. Close main power disconnect
3. Main power line fuses blown
a. Replace main power line Fuses
• Main cutting arc initiates
This completes the Main Arc Test. If the above are all
correct then the equipment should be operating properly.
If problems still persist then contact Technical Services.
4. Defective input power cable
a. Replace input power cable
5. Improper input power line connections inside Power
Supply
If the above does not function as noted then note the
symptom and proceed to Section 4.09, Main Arc Problems.
Manual 0-2697
a. Refer to Operating Manual, Section 3.07, Input
Power Cable Connections, and correct connections if necessary
4-7
SERVICE
6. Fuse blown inside Power Supply
a. Replace internal Fuse (F1)
E. AC indicator ON; TEMP indicator OFF; No gas flow;
GAS and DC indicators OFF
1. RUN/SET switch in RUN position
7. Voltage selection plug connected incorrectly
a. Switch to SET position
a. Refer to Operating Manual, Section 3.06 and correct
as needed
2. Gas supply not connected to unit
8. Faulty Auxiliary Transformer (refer to Appendix 12,
36 VAC Circuit Diagram)
a. Connect to gas supply
3. Gas supply not turned on
Measure for 36 VAC on Logic PC Board from J1-1
to J1-5.
a. Turn gas supply on
4. Faulty RUN/SET switch
a. If voltage is not present, replace the Auxiliary
Transformer
a. Check continuity
9. Faulty ON/OFF switch (refer to Appendix 12, 36 VAC
Circuit Diagram)
Measure for 36VAC on the Logic PC Board between J3-2 to J3-4.
a. If voltage is not present replace the ON/OFF
switch
5. Faulty gas solenoid circuit
a. Test gas solenoid circuit per Section 4.10-I; repair
as necessary
F. AC indicator ON; GAS indicator OFF; Gas flows; DC
indicator OFF
1. Gas pressure too low
10. Faulty Logic PC Board (refer to Appendix 12, 36 VAC
Circuit Diagram)
a. Set pressures above 35 psi (2.4 bar) limit of Plasma
Pressure Switch
Measure for 36 VAC on Logic PC Board from J5-1
to J5-3.
2. Faulty pressure switch
Measure for DC voltage from wire #51 to wire #50 at the
gas Pressure Switch at the rear of the Rear Panel Assembly.
a. If voltage is not present, replace the Logic PC
Board
D. AC indicator ON, TEMP indicator ON, RUN/SET
Switch is in RUN position, System will not pilot
a. If 12 vdc is present and pressure is above 35 psi (2.4
bar), replace gas Pressure Switch.
1. Air flow through unit is restricted
a. Provide adequate air flow (Refer to Operating
Manual, Section 3.02)
Rear Panel
2. Exceeded duty cycle of Power Supply
Gas Solenoid
a. Wait for fans to cool unit and (Refer to Section
3.03 for proper Duty Cycle
3. Fans not operating
Gas Pressure Switch
Measure for 115 VAC on the Logic PC Board from
J96-1 to J96-3 and J96-2 to J96-4.
Wire #51
• If voltage is correct, replace Fan Assembly
• If voltage is incorrect, replace Logic PC Board
Wire #50
4. Faulty temperature circuit
a. Check temperature circuit per Section 4.10-H;
repair as necessary
3. Low or No Coolant Flow
a. Check for proper coolant level. If low, fill to correct
level.
5. Defective Logic PC Board
On Logic PC Board remove J4 and J2 connectors
b. Check pump for proper operation (running) and replace pump if necessary.-
a. If TEMP Indicator stays ON then replace Logic
PC Board
SERVICE
A-01184
4-8
Manual 0-2697
4. Clogged coolant filter and/or in-line coolant filter
3. Faulty Pilot Output Board
a. Check internal and external coolant filters. Clean or
replace if necessary. Flush the old coolant from the
system.
a. Turn unit off.
b. Disconnect J12 and J13 from Pilot Output PC Board,
then check continuity at J12 pin 1 and pin 3 on the
Pilot Output Board. If shorted, replace Output PC
Board.
5. Clogged torch leads
a. Check torch and leads and replace if necessary.
Flush the old coolant from the system.
4. Faulty Logic Board
6. Faulty Flow Switch (FS1) or Logic PC Board
a. Disconnect J5 connector from Logic PC Board. If
D26 stays on, replace Logic PCB. If D26 goes out,
check wiring to J5 connector from Pilot PC Board.
a. Check the coolant flow switch and Logic Board
as follows:
The flow switch (FS1) for the coolant is calibrated for 0.25 gpm. When adequate coolant
flow satisfies FS1, it closes, connecting J99-1
on the Logic PC Board to J99-3 (common).
Measure voltage between J99-pin 1 and J99pin 3. If J99-1 is greater than 2 volts, FS1 or
connections to FS1 are faulty. If the voltage is
less than 2vdc, the Logic Board may be faulty.
Replace the flow switch or Logic Board as necessary.
G. AC Indicator ON; GAS Indicator ON; gas flows
continually
1. RUN/SET Switch in the SET position.
4.08 Pilot Arc Problems
NOTE
Refer to the Appendix Pages for PC Board Layouts.
Locate your symptom below:
A. AC Indicator ON; gas flows; GAS Indicator ON
when torch switch is closed; DC Indicator OFF or
flashes once. No spark or momentary spark at
torch
Measure for 320 vdc at Input PC Board between terminal
E8 wire #8 to E3 wire #9. If voltage is present, go to #4,
Faulty Logic or Gate PC Board.
a. Place Switch in RUN position.
1. Faulty Input "W" Contactor.
2. Faulty Gas Solenoid(s) or Logic PC Board
a. If Input "W" Contactor is not closing then measure the coil for 120VAC between wires #55 &
#59.
a. Turn the ON/OFF Switch to the OFF position.
• If the gas continues to flow, check the air filters or replace Solenoid(s).
• If voltage is not present, go to the next step.
• If voltage is okay, then replace Input "W"
Contactor.
• If the gas flow stops, replace the Logic PC
Board.
2. Faulty Logic PC Board
H. AC indicator ON; Gas flows; GAS and DC indicators ON; Arc in torch without pressing torch
switch; D26 (Torch Switch Enable) on Logic PCB
on
a. Measure for 120VAC at the Logic PC Board connector J2-1 and J2-4.
• If voltage is present, then check connections
to "W" coil.
1. Faulty Torch Switch
a. Refer to Torch Instruction Manual and check
continuity.
• If voltage is not present, measure for 120VAC
input to the Logic PC Board between J1-2 and
J1-6.
2. Faulty Torch Leads
• If voltage is present, replace the Logic PCB.
a. Disconnect the Torch Control Cable from the
J22 connector.
• If voltage is not present, continue to next
step.
b. If D26 on Logic PCB goes out, replace control
cable in leads package.
Manual 0-2697
4-9
SERVICE
3. Faulty Auxiliary Transformer (T3)
6. Faulty Output Pilot PC Board (see note above)
a. Measure for 120VAC between T3 connector J30-2
to J30-6.
a. Test per section 4.10-J. repair as necessary.
b. Disconnect and isolate wires from E8 on Pilot Output PC Board.
• If voltage is okay, check connections to Logic
PC Board.
c. Following the procedure detailed in 4.10-K.1, measure the output voltage at the FET Heatsink assembly between E-17 & E-18. If voltage is okay with
wires disconnected, replace Output Pilot PC Board.
• If voltage is not present, replace the T3 Auxiliary Transformer.
NOTE
7. Faulty FET PC Board
For #4 through #6 below, J-11 should be disconnected and isolated from the CD PC Board and the
torch switch will need to be closed.
a. Check per section 4.10-K. Repair or replace as necessary.
4. Faulty Logic PC Board or Gate PC Board (see note
above)
B. AC indicator ON; Gas flows; GAS indicator ON; DC
indicator blinks; Small arc may be visible in torch
1. Shorted torch
a. Close the torch switch. The LED D20 on the
top Gate PC Board should turn off.
a. Remove torch from bulkhead connections. Measure between Pilot Return Lead and Torch (-). If the
meter doesn't show an open, repair torch.
• If LED D20 does not turn off, measure for 12
vdc to drop to less than 2 vdc between J9-12
to J9-11.
2. Faulty Pilot Output PC Board
• If voltage does not drop, replace the Logic
PC Board.
a. Test per Section 4.10-J; repair as necessary
3. Faulty FET/Heatsink Assembly
• If voltage drops to less than 2 vdc, replace
the Gate Drive PC Board.
• If LED D20 does turn off, D4 should flash on/
off once two seconds later.
• If D4 does not flash on/off once, measure
for 12 vdc to drop to less than 2 vdc momentarily, between J9-14 to J9-13 on the top
Gate Drive PC Board.
• If the voltage does not drop momentarily, then replace the Logic PC
Board.
• If the voltage does drop momentarily,
replace the Gate Drive PC Board.
a. Check per Section 4.10-K; repair as necessary
C. AC indicator ON; Gas flows; GAS and DC indicators
ON; No arc in torch; No arc at spark gap on CD PC
Board; CD enable indicator D25 on Logic Board ON
1. Faulty CD PC Board
Measure DC voltage between J11-4 to J11-5 on CD PC
Board
a. If voltage is less than 2 vdc replace CD PC Board
D. AC indicator ON; Gas flows; GAS and DC indicators
ON; Spark at gap on CD PC Board and CD enable
indicator (D25) on Logic PC Board ON; No arc or
intermittent arc in torch
• If D4 on the Gate PC Board does flash for two
seconds after D20 turns off, then go to the next
step.
5. Faulty Torch or Leads (see note above)
a. Remove wire 15 from Pilot Output PC Board
terminal E24.
b. Following the procedure detailed in 4.10-K.1,
measure the output voltage at the FET Heatsink Assembly between E-17 & E-18. If voltage is okay with wires disconnected, repair or
replace torch/leads as required.
1. Gas pressure(s) set incorrectly (too high)
a. Check gas pressures. Plasma Gas Pressure should
be 65 psi (4.5 bar), and Secondary Gas Pressure
should be 60 psi (4.1 bar).
2. Oil/moisture in air lines
a. Purge system. If problem corrected add filters in
line with air source
3. Incorrect torch parts
a. Refer to appropriate Torch Instruction Manual
4. Faulty leads
SERVICE
4-10
Manual 0-2697
a. Check continuity per appropriate Torch Instruction
Manual
4.09 Main Cutting Arc Problems
NOTE
5. Faulty torch
Refer to the Appendix Pages for PC Board Layouts.
a. Check continuity per appropriate Torch Instruction
Manual
6. Faulty connection of wire #15 or #17 to Pilot Output
PC Board or pilot inductor wires reversed with wire
#17.
Locate your symptom below:
A. Main cutting arc will not initiate
1. Work cable not connected.
a. Check wiring connection
a. Connect work cable.
7. Faulty Pilot Output PC Board
2. Faulty INR Inrush Contactor
a. D5 on the Pilot PC Board should turn on two
seconds after the torch switch is closed.
a. While attempting to transfer, measure for 0vdc
at input PC Board between E1 and E8.
• If D5 does turn on, install a jumper between
E22 and E8 on the Pilot PC Board. If unit
will pilot with jumper installed, replace the
Output PC Board.
• If the voltage is correct, then replace the
INR Inrush Contactor.
• If voltage is not 0vdc then measure for
120VAC at INR inrush contactor coil wires
#68 and #69.
• If D5 does not turn on, measure the 12 vdc
to drop to less than 2 vdc between J13-18
& J13-17 two seconds after torch switch is
closed. If voltage does drop, then measure
for 36 VAC between J13-14 & J13-15. If
36VAC is found then replace the Pilot/Output PC Board.
3. Faulty Logic PC Board
a. If 120VAC is not found at INR Inrush Contactor
wires #68 and #69, measure for 120VAC at the
Logic PC Board between J2-4 to J4-8.
• If 120VAC is not present, replace the Logic
PC Board.
8. Faulty Logic PC Board
a. If the voltage between J13-18 & J13-17 on the
Pilot/Output PC Board does not drop to less
than 2 vdc two seconds after the torch switch
is pressed, replace the Logic PC Board.
• If 120VAC is present, check wiring.
4. Faulty Current Sensor PC Board
Check the following:
a. While trying to initiate main cutting arc, measure the voltage at J99-6 to J99-7 (or TP 10 to
Gnd) indicators inside the Power Supply.
• If voltage is approximately 12 vdc replace
the Current Sensor.
• If voltage is less than 2 vdc replace the
Logic PC Board.
5. Faulty Transfer Mod Enable Signal
a. Test this Signal by measuring J4-6 to J4-8.
• If voltage approximately 12 vdc, replace
Logic Board
• If 0vdc, replace Gate Drive Board
Manual 0-2697
4-11
SERVICE
6. Misaligned plugs can cause printed circuit board damage.
Be sure plugs are properly aligned and completely seated.
B. When operating at amperages over 35 amps the amperage drops off after main cutting arc initiates
Check whether Drag indicator (D31) on the Logic PC Board
is ON when the torch tip comes in contact with the workpiece.
7. Excessive pressure can damage printed circuit board. Use
only minimal pressure and gentle movement when disconnecting or connecting printed circuit board plugs.
1. Cutting tip in contact with the workpiece.
B. Opening Power Supply Enclosure
a. Maintain standoff distance 1/8"-3/8" between cutting tip and workpiece.
2. Faulty Logic PC Board
Remove the left side panel of the Power Supply for access to the input power connections and the input voltage selection.
If torch tip is off the workpiece and the drag indicator,
D31, on the Logic PC Board is still ON, then replace the
Logic PC Board.
WARNING
Disconnect primary power at the source before assembling or disassembling the Power Supply, torch
parts, or torch and leads assemblies.
C. Main cutting arc will not shut off when torch signal is
deactivated
1. STANDARD/LATCH Switch in LATCH position
a. Place switch to STANDARD position.
1. Remove input power from the unit.
2. Faulty STANDARD/LATCH Switch
a. Test switch for open condition when in STANDARD position and replace if necessary.
2. Loosen the two bottom screws in the slotted holes of
the desired Side Panel (viewed from the front of the
unit).
3. Remove the remaining screws which secure the Side
Panel to the Power Supply.
3. Faulty Logic PC Board or Wiring Harness
Disconnect STANDARD/LATCH Switch from
wiring harness at J28 and retest system.
• If main arc will shut off, then Logic PC Board
is faulty.
4. Pull the top of the Side Panel out and then lift up to
remove the panel from the Power Supply a short distance (see NOTE).
NOTE
• If main arc will still not shut off, then wiring
harness is faulty. Repair as necessary.
4.10 Test Procedures
There is a ground wire connection to the Side Panel
on the inside of the unit.
5. Remove the nut securing the ground wire to the side
panel and remove the ground wire.
The test procedures in this subsection are referenced in
the troubleshooting section.
6. Remove Side Panel from unit and set aside.
A. Safety Precautions
1. Significant DC voltage exists after removal of input
power. Allow 2 minutes for discharge time. Voltage
measured on input capacitors must be zero before performing service on the power supply.
2. Do Not touch electrical components with any part of
the human body when power is applied.
3. Keep away from any moving parts.
4. Hot surfaces can cause severe burns. Allow equipment to cool before servicing.
5. Electrostatic discharge can damage printed circuit board
assemblies. Transport printed circuit boards in proper antistatic shielded packages. Use proper grounding techniques
with wrist strap before handling printed circuit boards.
SERVICE
4-12
Manual 0-2697
Art # A-00307
0.75
NOTE
Art may differ
from actual unit.
Forward Bias
Diode Conducting
Diode Test Symbol
VR COM
_
+
Anode
A
A-03045
Cathode
Testing Diode Forward Bias
7. Reinstall the Side Panel as follows:
a. Reconnect the ground wire to the Side Panel, if disconnected.
b. Place the Side Panel onto the frame and slide the top
edge under the lip on the Top Panel.
6. Reverse the meter leads across the diode for reverse bias
testing (refer to following figure). A properly functioning
diode will block in the reverse bias direction and depending
on the meter function will indicate an open or “OL”.
Art # A-00306
c. Reinstall all the screws to secure the Side Panel.
OL
C. Diode Testing Basics
Testing of diode modules requires a digital volt/ohmmeter that
has a diode test scale. Remember that even if the diode module
checks good, it may still be bad. If in doubt, replace the diode
module.
Reverse Bias
Diode Not Conducting
1. Locate the diode module to be tested.
2. Remove cables from mounting studs on diodes to isolate
the module.
Cathode
VR COM
_
+
A
3. Set digital volt/ohmmeter to diode test scale.
4. Using the Figures for each test, check each diode in the
module. Each diode must be checked in forward bias (plus
to negative) and reverse bias (negative to plus) direction.
5. Connect the volt/ohmmeter positive lead to the anode (+)
of the diode and the negative lead to the cathode (-) of the
diode for forward bias testing (refer to following figure). A
properly functioning diode will conduct in the forward bias
direction and indicate between 0.3 to 0.9 volts.
Manual 0-2697
Anode
Testing Diode Reverse Bias
7. If a diode checks bad, replace the diode module.
8. Reconnect all cables to proper terminals.
4-13
SERVICE
D. Input PC Board /Input Bridge Rectifier
Test
E. Main Contactor (MC1) Test
Locate the Input PC Board and check for shorted input diode.
NOTE
Refer to Appendix Pages for PC Board Layouts.
Remove AC power and with an ohmmeter set on the diode
range make the following checks:
Reconnect power and observe proper start-up procedure. Indicator D47 on the Logic PC Board should be ON. If indicator
D47 is OFF there is no voltage to the Power Supply or an overvoltage condition exists.
If indicator D47 is OFF check L1, L2, and L3 for proper AC input
voltage.
Main Contactor
(MC1)
Meter (+)
Meter (-)
L3
L2
Indication
A
(-)
Open
B
(-)
Open
C
(-)
Open
A
(+)
Diode Drop
B
(+)
Diode Drop
C
(+)
Diode Drop
(+)
(-)
Open
L1
Coil
Wire #55
Coil
Wire #59
A-01195
Measure voltage on coil of contactor, approximately 115 VAC
between wires #55 and #59.
The meter should indicate a diode drop in one direction and an
open in the other direction for each check.
• If voltage is correct, replace Main Contactor.
• If voltage is incorrect, replace Logic PC Board.
If Input Bridge Rectifier diode(s) shorted, make the following
checks with an ohmmeter at the Main Contactor:
NOTE
The Main Contactor was located in the Base on
earlier units and on the Center Chassis for current
units.
M e t e r (+ )
M e t e r (-)
I n d ic a t io n
L1
T1
O pen
F. Inrush Relay Test
L2
T2
O pen
L3
T3
O pen
If after approximately 8 seconds, the Inrush Relay does
not engage, measure for 115VAC on wires #68 and #69. If
there is voltage, replace Contactor. If there is no voltage,
measure at Logic Board J17- 4 to J17-8. If there is no voltage at the Logic Board, replace Logic Board.
If any test has resistance, then replace the Main Contactor
also.
G. Blown Fuse (F1) Test
1. The voltage selector set to the wrong input voltage will cause F1 to fail.
a. Verify input voltage with Voltage Selector.
2. A shorted or frozen pump/motor will cause F1
to fail. To check the motor:
a. Replace F1 fuse and unplug J32
b. Turn power on if fuse is okay.
• Check motor connections
• Check voltage to motor connector
SERVICE
4-14
Manual 0-2697
9. Repeat steps 1-8 for each FET Assembly.
H. Temperature Circuit Test
If the TEMP Indicator is still on, go to the next step.
The Power Supply has seven temperature sensing switches.
10. Check the Temperature Switch at the Input Bridge Diode, by completing the following:
• One on each FET Heatsink Assembly (four total)
• One located behind the Input Board near the Input Bridge
Diode.
• Make sure power is off at the wall disconnect.
• One on the Pilot/Output Heatsink
• Remove one connection from the Temp switch located behind the Input PC Board.
• One on the Radiator
If any one of these sense overtemperature, the Overtemp Indicator on the Access Panel will light and not allow DC output.
• Turn the unit back on.
If the Temp Indicator is off, remove power and replace
Temp Switch.
NOTE
Refer to the Appendix Pages for PC Board Layouts.
If the Temp Indicator is still on, go to the next step.
11. Check the Pilot/Output Board.
Test the temperature circuit per the following:
• Remove power then disconnect J13 on Pilot Output Board
1. Place the front panel ON/OFF switch to the OFF
position.
• Turn power back on and check the TEMP Indicator.
2. Disconnect ribbon cable from the FET/Heatsink
Assembly at J6.
If the Indicator has gone off, replace Pilot Output PC
Board.
A-01410
If the TEMP Indicator is still on, continue with the next
step.
FET/Heatsink and
Capacitor PC Board
Assembly
12. Unplug J2 on the Logic Board.
13. Place the ON/OFF switch in the ON position.
If the TEMP indicator is off replace the Temperature
Switch on the Radiator.
If the TEMP indicator is still on replace the Logic Board.
I.
Gas Solenoid Circuit Test
NOTE
J6
Refer to the Appendix Pages for PC Board Layouts.
3. Place the front panel ON/OFF switch to ON.
4. Check the status of the TEMP indicator.
a. If indicator has gone OFF, then remove power
and replace the corresponding pair of FET/
Heatsink Assemblies.
Make the following voltage checks per the circuit diagram and replace the faulty part as required.
1. Place the RUN/SET Switch in the SET position
and check for 115 VAC from wire #56 to wire #52
at the plasma gas Solenoid.
b. If the indicator is still on, go to the next step.
If approximately 115 VAC replace Solenoid.
5. Place the front panel ON/OFF switch to the OFF
position.
If no voltage is present proceed to Step 2.
6. Disconnect ribbon cable from the next FET/Heatsink Assembly at J6.
2. Measure for 115 VAC from J2-2 to J17-3 at the Logic PC
Board.
7. Place the front panel ON/OFF switch to ON.
If voltage is not correct replace Logic PC Board.
8. Check status of the TEMP Indicator. If Indicator is
OFF, remove power and replace the upper or lower pair
of FET/Heatsink Assemblies.
Manual 0-2697
3. Check for 115VAC from wire #64 to wire #65 at the
secondary gas Solenoid.
4-15
SERVICE
If approximately 115VAC is present, replace Solenoid.
vdc, indicating a problem exists, the Logic PC Board sends
a signal which turns OFF the PWM Enable signal to the
Gate Drive PC Board. Because this happens in less than 50
milliseconds, it is not easy to take voltage readings to find
the source of the problem.
If no voltage is present, proceed to step 4.
4. Measure for 115VAC from J17-7 to J2-6 at the Logic
Board.
When the unit is at “idle” the AC OK indicator, D47, should
be ON. The Torch Switch Enable indicator, D26, turns ON
when the torch switch is pressed. At this point the gas
begins to flow. When the preflow time is over the PWM
Enable signal is given and the DC indicator at the front
panel turns ON.
If the voltage is not correct, replace the Logic
Board.
J. Pilot Arc Circuit Test
NOTE
Refer to the Appendix Pages for PC Board Layouts.
If the front panel DC Indicator turns ON then OFF immediately, the following test should be performed:
Check across E23 to E24 at the Pilot Output PC Board.
There should be a diode drop across E23 to E24 in
one direction and an open in the other.
a. Disconnect J11 from the CD PC Board to disable
the CD signal.
b. Connect a jumper between TP1 and TP8 on Logic
PC Board. This will cause the gas to flow continuously and the DC Indicator on the front panel to
turn ON.
If shorted remove the wires at E23 and E24 at the
Pilot Output PC Board and check again.
Replace Pilot Output PC Board if shorted from E23
to E24 (with wires removed).
K. FET/Heatsink Circuit Tests
WARNING
NOTE
Connector J11 on the CD PC Board must be disconnected to prevent electrical damage to measuring equipment when testing the open circuit voltage (OCV).
Refer to the Appendix Pages for PC Board Layouts.
The FET/Heatsink circuit tests require various checks to
isolate the possible fault to the FET/Heatsink Assembly.
c. Press and hold the hand torch switch (Logic
PC Board Start Indicator, D26, turns ON).
There are several internal indicators (LED's) on the Logic
PC Board, Pilot/Output PC Board and the Gate Drive
PC Board to help in troubleshooting. They are as follows:
d. Measure open circuit voltage between E8 (+)
to E7 (-) at the Pilot Output PC Board. If voltage is low, each FET/Heatsink Assembly
should be tested individually.
NOTES
The upper FET Assemblies provide the power for
piloting and the main cutting arc. The lower FET
Assemblies are for main cutting arc only.
2. FET/Heatsink Output Diode Checks
Remove input power from the unit.
The upper Gate Drive Board controls the upper
two FET/Heatsink Assemblies and the lower Gate
Drive Board controls the bottom two FET/Heatsink Assemblies.
Isolate each FET/Heatsink Assembly by removing the red
wire #12 at E18 and the black wire #11 at E17 on each FET/
Heatsink Assembly. With an ohmmeter set on the diode
1. NoDCOutput
An open circuit voltage of approximately 280 to 325 vdc
(depending on input power selected) is produced when
switching transistors in the FET/Heatsink Assemblies are
turned ON by a PWM Enable signal from the Logic PC
Board. A circuit on the Logic PC Board monitors the output voltage. When the output voltage drops below 60
SERVICE
4-16
Manual 0-2697
range, check between the two output studs, E17 (- output)
to E18 (+ output). This should indicate a diode drop in one
direction and open in the other.
Be sure that the meter lead probes penetrate the
protective coating on the MOSFET.
d. Place the meter (+) lead on drain lead of Q1 and
meter (-) lead to the heatsink. The meter should
indicate >1 meg ohms.
If the checks indicate shorted or open in both directions
then the faulty pair of FET/Heatsink Assemblies should be
replaced.
e. Place the meter (+) lead on gate lead of Q6 and
meter (-) lead on source lead of Q6. The meter
should indicate approximately 2.5K ohms.
3. MOSFET Resistance Checks
The Power Supply contains four identical FET/Heatsink
Assemblies. On each assembly there are two MOSFET
devices that must be checked. Use an ohmmeter to check
for the proper resistance of the MOSFET's as follows:
a. Locate Q1 and Q6 on the FET/Heatsink Assembly.
Q6
f. Place the meter (+) lead on drain lead of Q6 and
meter (-) lead on source lead of Q6. The meter
should indicate >100K ohms.
4. FET Reset Diode Check
Use an ohmmeter set to the diode function and check
the reset diode as follows:
Q1
FET/Heatsink and
Capacitor PC Board
Assembly
a. Place the meter (+) lead on E14 and the meter (-)
lead on E12 of the FET/Heatsink Assembly Capacitor PC Board to check the reset diode. The
meter should indicate between 0.4 to 0.6 volts using the diode function.
b. Reverse the meter leads and the indication should
be a capacitor charging.
c. Place the meter (-) lead on E14 and the meter (+)
lead on E13 of the FET/Heatsink Assembly Capacitor PC Board to check the reset diode. The
meter should indicate between 0.4 to 0.6 volts using the diode function.
A-01414
b. Place the meter (+) lead on gate lead of Q1 and meter () lead on source lead of Q1. The meter should indicate
approximately 2.5K ohms.
Spring
Clip
d. Reverse the meter leads and the indication should
be a capacitor charging.
If the indication is a short, then replace the upper or
lower pair of FET/Heatsink Assemblies.
MOSFET
5. FET Output Rectifier Check
NOTE
Gate
A-00553
c.
Drain
Refer to the Appendix Pages for PC Board Layouts.
Source
Place the meter (+) lead on drain lead of Q1 and meter
(-) lead on source lead of Q1. The meter should indicate >100K ohms.
NOTES
Make measurements near the body of each
MOSFET.
Manual 0-2697
4-17
SERVICE
Use a digital meter, diode or ohms function, to check the
forward and reverse bias of the output rectifiers on the
FET/Heatsink Assemblies as follows:
6. FET Output Clamp Diodes Check
a. Remove the wire from E16 and E18 on the Upper and
Lower FET/Heatsink Assemblies.
NOTE
Refer to the Appendix Pages for PC Board Layouts.
Use an ohmmeter to check the resistance of the output clamp diodes, (+ out) E17 and (- out) E18, as follows:
A-01415
E14
E15
NOTE
E19
The wires on E16 and E18 should still be disconnected from both FET/Heatsink Assemblies.
a. Place the meter (+) lead on E17 and the meter (-)
lead on E18 of the FET/Heatsink Assembly to
check the output clamp diode resistance. The
meter should indicate >1 meg ohms.
E17
E18
E16
b. Place the meter (+) lead on E16 and the meter (-) lead on
E18 of the FET/Heatsink Assembly to check the output
rectifier forward bias. The meter should indicate between 0.3 to 0.6 volts using the diode function or 100K
ohms using the ohms function.
c. Place the meter (+) lead on E18 and the meter (-) lead on
E16 of the FET/Heatsink Assembly to check the output
rectifier reverse bias. The meter should indicate 'OL'
using the diode function or 100K ohms using the ohms
function.
b. Place the meter (+) lead on E18 and the meter (-)
lead on E17 of the FET/Heatsink Assembly to
check the output clamp diode resistance. The
meter should indicate >1 meg ohms.
Replace the the upper or lower pair of FET/Heatsink Assemblies if any of the above tests are open or
shorted.
CAUTION
The FET/Heatsink Assemblies are matched and balanced during production and must be replaced in
pairs.
d. Place the meter (+) lead on E17 and the meter (-) lead on
E19 of the FET/Heatsink Assembly to check the output
rectifier forward bias. The meter should indicate between 0.3 to 0.6 volts using the diode function or 100K
ohms using the ohms function.
e. Place the meter (+) lead on E19 and the meter (-) lead on
E17 of the FET/Heatsink Assembly to check the output
rectifier reverse bias. The meter should indicate 'OL'
using the diode function or 100K ohms using the ohms
function.
f. Place the meter (+) lead on E18 and the meter (-) lead on
the heatsink of the FET/Heatsink Assembly to check
the output rectifier resistance to ground. The meter
should indicate >1 meg ohms.
Replace the upper or lower pair of FET/Heatsink Assemblies. if any of the above tests are open or shorted.
SERVICE
4-18
Manual 0-2697
SECTION 5:
REPLACEMENT
PROCEDURES
B. Procedure
1. Open the wrist strap and unwrap the first two folds of
the band. Wrap the adhesive side firmly around your
wrist.
2. Unroll the rest of the band and peel the liner from the
copper foil at the opposite end.
5.01 Introduction
3. Attach the copper foil to a convenient and exposed
electrical ground.
This section describes parts replacement procedures and all
cable repairs which may be performed on the Pak Master 150XL
Power Supply.
4. Connect the equipment primary cable ground to
the same electrical ground as the wrist strap.
Under no circumstances are field repairs to be attempted on
Printed Circuits or other Subassemblies of this unit. Evidence
of unauthorized repairs may void the factory warranty.
5. Open the equipment enclosure (see instruction
manual for the appropriate equipment) and remove the failed PC Board.
5.02 Anti-Static Handling
Procedures
6. Carefully open the ESD protective bag and remove the replacement PC Board.
A. General
7. Install the replacement PC Board in the equipment
and make all necessary connections.
8. Place the failed PC Board in the ESD protective
bag and seal for return shipping.
CAUTION
PC Boards can be irreparably damaged by improper
handling due to electrostatic discharge (ESD).
9. Reassemble the equipment enclosure (see instruction manual for the appropriate equipment).
Replacement PC boards are shipped in a protective enclosure to prevent damage from electrostatic discharge
(ESD) during shipping. Included with each replacement
board is a ground strap to prevent static damage during
installation.
10. Remove the grounding wrist strap from your
wrist and from the electrical ground connection
before reconnecting primary power to the equipment.
WARNINGS
Read and understand these instructions and the
instructions on the grounding wrist strap package
before opening the equipment enclosure or removing the replacement PC Board from its protective
enclosure.
Disconnect primary power to the system before disassembling the torch, torch leads, or power supply
enclosure.
Do not operate the equipment or test equipment
under power while wearing the grounding wrist
strap.
Manual 0-2697
5-1
REPLACEMENT PROCEDURES
4. Pull the top of the Side Panel out and then lift up to
remove the panel from the Power Supply a short distance (see NOTE).
5.03 Parts Replacement - General
Information
The parts replacement procedures described in this
manual require that the Power Supply be disassembled.
The part to be replaced will determine to what extent the
Power Supply must be disassembled.
NOTE
There is a ground wire connection to the Side
Panel on the inside of the unit.
5. Remove the nut securing the ground wire to the
side panel and remove the ground wire.
Before disassembling any part of the Power Supply first
read the procedure for the part to be replaced, then proceed with the disassembly.
6. Remove Side Panel from unit and set aside.
NOTES
Before removing any electrical connection mark
each wire with the connection designation. When
reassembling this makes sure the wires go to the
proper terminals.
NOTE
Art may differ
from actual unit.
Note the routing of wires and make sure the wires
are put back in the same place when reassembling
the unit.
Turn OFF all gas inputs to the Power Supply at
the source before disconnecting any gas Hose Assemblies.
Each Subsection is referenced to Section 6 for parts lists and
overall detailed drawing.
A-03045
WARNING
Figure 5-1 Side Panel Removal
Disconnect primary power from the source before
opening or disassembling the power supply. Make
sure AC indicator on the Power Supply front panel
is OFF.
7. Install the replacement Side Panel by reversing the
above procedure as follows:
a. Reconnect the ground wire to the Side Panel,
if disconnected.
b. Place the Side Panel onto the frame and slide
the top edge under the lip on the Top Panel.
5.04 Major External Parts
Replacement
c. Reinstall all the screws to secure the Side Panel.
NOTE
B. Top Panel Replacement
Refer to Section 6.03 for parts list and overall detail drawing.
1. Remove the Left Side Panel per Section 5.04-A.
2. Remove the screws securing the Top Panel to the
side and rear panels.
A. Left or Right Side Panel Replacement
1. Remove input power from the unit.
3. Locate and remove the nut securing the Top Panel
to the center chassis.
2. Loosen the two bottom screws in the slotted holes
of the desired Side Panel (viewed from the front
of the unit).
4. Slide the Top Panel stud out of the center chassis
hole.
3. Remove the remaining screws which secure the
Side Panel to the Power Supply.
REPLACEMENT PROCEDURES
5. Install the replacement Top Panel by reversing the
above procedure.
5-2
Manual 0-2697
C. Work Cable Replacement
1. Remove Right Side Panel per Section 5.04-A.
5.05 Access Panel Parts
Replacement
2. Remove the work cable strain relief from the Front Panel.
NOTE
3. Disconnect work cable connection from E8 on Pilot
Output PC Board.
4. Pull the work cable through the Current Sense PC Board
and then through the Front Panel, then remove from
unit.
Refer to Section 6.04 for parts list and overall detail drawing.
A. CURRENT Knob Replacement
1. Turn the CURRENT adjustment fully counter
clockwise and note the location of the pointer at
the 30 on the knob.
5. Install the replacement work cable by reversing the
above procedure.
2. Loosen the screw securing the Current Knob to
the potentiometer shaft.
D. Torch & Leads Assembly Replacement
1. Open the Access Panel per Section 5.05-E.
3. Remove knob.
2. Disconnect all hoses and the cable from the bulkhead.
3. Disconnect Shield Wire from Shield Stud, if present on
Torch Lead
4. Place the replacement Current Knob on to the potentiometer shaft with the location of the pointer the same
as noted in step 1.
4. Install the replacement Torch Assembly by reversing
the above procedure, keeping in mind the following:
5. Tighten the screw to secure the knob to the potentiometer shaft.
a. Connect the bottom hoses first.
B. ON/OFF Switch (SW1) Replacement
1. Unlatch the Access Panel to gain access to the rear of
the ON/OFF Switch.
b. The two fittings on the right side of the bulkhead
(when viewed from the front of unit) are for left
hand hoses; the two fittings on the left are for right
hand hoses.
2. Disconnect all the wiring to the ON/OFF Switch. Wiring is as follows:
E. Front Panel Replacement
On/Off Switch
1. Remove the Left and Right Side Panels per Section 5.04-A.
2. Remove the Work Cable per Section 5.04-C.
wire #32
3. Remove the Torch & Leads per Section 5.04-D.
wire #33
4. Remove the two bolts at the bottom of the Front
Panel.
5. Remove the nuts on the inside of unit securing
the Front Panel to the two studs on the center chassis.
1A
5B
2A wire #35
A-02285
3. Squeeze the top and bottom of the switch while pulling
it out of the Access Panel.
6. Carefully remove Front Panel from the unit.
4. Install the replacement ON/OFF Switch by reversing
the above procedure.
7. Install the replacement Front Panel by reversing
the above procedure.
Manual 0-2697
wire #34
4B
5-3
REPLACEMENT PROCEDURES
C. RUN/SET Switch (SW2) Replacement
E. Pot/LED PC Board Assembly Replacement
1. Unlatch the Access Panel to gain access to the rear of
the RUN/SET Switch.
1. Turn the CURRENT adjustment fully counter
clockwise and note the location of the pointer on
the knob.
2. Disconnect all the wiring to the RUN/SET Switch. Wiring is as follows:
2. Loosen the screw securing the Current Knob to the
potentiometer shaft.
Run/Set Switch
3. Remove the Current Knob.
4. Unlatch the Access Panel to gain access to the Pot/
LED PC Board.
5. Remove the Pot/LED PC Board from the four
standoffs.
wire #30
wire #31
6. Disconnect the wire harness on Pot/LED PC
Board.
A-02284
7. Install the replacement Pot/LED PC Board by reversing the above procedure.
3. Squeeze the top and bottom of the switch while pulling
it out of the Access Panel.
4. Install the replacement RUN/SET Switch by reversing
the above procedure.
F. Access Panel Replacement
1. Turn the two Dzus studs 1/4 turn each to unlatch
Access Panel from Front Panel.
D. STANDARD/LATCH Switch (SW3)
Replacement (See NOTE)
2. Lift Access Panel straight up then down until the
side hinges lock into place.
NOTE
3. Disconnect the ground wire on the Access Panel.
STANDARD/LATCH Switch was not available on
earlier units.
4. Remove the following components from the Access Panel by referring to :
1. Unlatch the Access Panel to gain access to the rear of
the STANDARD/LATCH Switch.
• ON/OFF Switch per paragraph 5.05-B.
2. Disconnect all the wiring to the STANDARD/LATCH
Switch. Wiring is as follows:
• RUN/SET Switch per paragraph 5.05-C.
• STANDARD/LATCH Switch per paragraph
5.05-D.
STANDARD/LATCH Switch
• Current Knob and Pot/LED PC Board per
paragraph 5.05-E.
5. To remove the Access Panel, lift up and pull straight
out to disengage the Access Panel side hinges and
remove the panel from the unit.
Wire To J28-3
6. Install the replacement Access Panel by reversing the
above procedure.
A-03057
Wire To J28-1
3. Squeeze the top and bottom of the switch while pulling
it out of the Access Panel.
4. Install the replacement STANDARD/LATCH Switch
by reversing the above procedure.
REPLACEMENT PROCEDURES
5-4
Manual 0-2697
5.06 Left Side Center Chassis Parts
Replacement
C. Input PC Board Assembly Replacement
1. Remove the Left Side Panel per Section 5.04-A.
2. Disconnect all cable lug connections to Input Board,
removing star washers and nuts where applicable.
NOTE
Refer to Section 6.05 for parts list and overall detail drawing.
A. Fuse (F1) Replacement
Connection
Description of Cable
1. Remove power from unit.
A
Cable #1 from W Contactor
2. Remove the Left Side Panel per Section 5.04-A.
B
Cable #2 from W Contactor
C
Cable #3 from W Contactor
E1
Wire #8 from Voltage Selection
Base; Wires 8E from INR
Contactor Positions L3 & L4
E2
Wire #8 from Voltage Selection
Base; Wires 8E from INR
Contactor Positions L1 & L2
E3
Wire #9 From Voltage
Selection Base
3. Disconnect two wires connected to Fuse Holder.
E4
Wire #9 from Voltage Selection
Base
4. Remove the two small screws securing Fuse Holder to
the chassis.
E7
Wires 8E from INR Contactor
Positions T3 & T4
5. Install the replacement Fuse Holder by reversing the
above procedure.
E8
Wires 8E from INR Contactor
Positions T1 & T2
3. Remove Fuse from the fuse holder.
4. Replace Fuse (5 amp, 600V).
5. Reinstall Left Side Panel.
B. Fuse Holder Replacement
1. Remove the Left Side Panel per Section 5.04-A.
2. Remove Fuse from Fuse Holder.
NOTE
Refer to reverse side of replacement board for connection identification.
3. Remove the clear insulator sheet from the Input
Board.
4. Remove the three screws in top holes connecting the
Input Board to the Bridge Rectifier.
5. Install the replacement Input PC Board by reversing
the above procedure noting the following:
• The three screws securing the wiring and Input PC
Board to the Bridge Rectifier must be tight enough
to prevent the wires from moving.
NOTE
Failure to properly tighten the three screws securing the Input PC Board to the Bridge Rectifier
will cause damage to the unit.
• Prior to making cable connections, peel protective
coating off insulator sheet and place insulator sheet
on replacement input board.
Manual 0-2697
5-5
REPLACEMENT PROCEDURES
D. Input Bridge Rectifier Replacement
G. Logic PC Board Replacement
1. Remove the Left Side Panel per Section 5.04-A.
1. Remove the Left Side Panel per section 5.04-A.
2. Remove the Input PC Board per Section 5.06-C.
2. Carefully remove all cable connections from the Logic
PC Board noting the location of each.
3. Remove the two nuts securing the Bridge Rectifier to
the Heatsink.
3. Remove the five screws securing the Logic PC Board
to the standoffs.
4. Remove the Bridge Rectifier Assembly from the unit.
4. Install the replacement Logic PC Board by reversing
the above procedure.
5. Remove the Thermal Pad.
6. Install the replacement Input Diode Bridge Assembly,
including Thermal Pad by reversing the above procedure, noting the following:
H. Gate Drive PC Board(s) Replacement
NOTE
• Clean Heatsink and back of Bridge Rectifier surface with a clean rag and alcohol.
The two Gate Drive Boards are identical and are
removed in the same manner.
• The two nuts removed in Step 3 must be torqued to
35 in-lbs when reinstalled.
1. Remove the Left Side Panel per Section 5.04-A.
2. Carefully remove all cable connections to the Gate
Drive PCB Assembly noting the location of each
per the following chart:
• Install Rectifier with A B C terminals away from the
Thermostat.
E. Thermostat (TS2) Replacement
1. Remove the Left Side Panel per Section 5.04-A.
Connection
2. Remove the Input PC Board per Section 5.06-C.
3. Remove two screws securing the Thermostat to the
Heatsink.
4. Install replacement Thermostat by reversing the above
procedure.
F. In-Rush Contactor (INR) Assembly
Replacement
J7
Ribbon Cable from
FET/Heatsink Assembly
J8
Ribbon Cable from
FET/Heatsink Assembly
J9
Ribbon Cable from logic
Board at J4 to both Gate
Drives at J9
J10
Twisted 3-wire harness
from J11 on top Gate Drive
Board
J11
Twisted 3-wire harness
from J10 on bottom Gate
Drive Board
1. Remove the Left Side Panel per Section 5.04-A.
2. Note orientation of all the wires connected to the
Contactor Assembly and label them.
3. Disconnect the wires from the Contactor Assembly terminals.
4. Remove the two nuts and washers securing the
Contactor Assembly to the internal chassis of the
unit.
3. Remove the four screws securing the Gate Drive
PC Board to the four standoffs.
5. Install the replacement Contactor Assembly by reversing the above steps, keeping in mind the following:
4. Reinstall the replacement Gate Drive PCB Assembly by reversing the above procedure.
• Install Contactor with T1-T4 side towards heatsinks.
REPLACEMENT PROCEDURES
Description of Cable
5-6
Manual 0-2697
I.
FET/Heatsink Assembly Replacement
CAUTION
Replace As
Pair
The FET/Heatsink Assemblies are matched and
balanced during production and must be replaced
in pairs.
NOTE
Replace As
Pair
The four FET/Heatsink Assemblies are identical
and are removed in the same manner.
1. Remove the Left Side Panel per Section 5.04-A.
A-02584
2. Remove the Ribbon Cable plugs at J6 on the FET/
Heatsink Assembly. To remove the cable, push
down on the locking tab and pull the cable plug
out of the connector.
8. Install the replacement FET/Heatsink Assembly by reversing the above procedure.
NOTE
3. Disconnect all the wire lug connections to the FET/
Heatsink Assembly.
Connection
Be sure that the top groove in the FET/Heatsink
Assembly is properly seated over the cutout in the
chassis.
Description
E14
Main Transformer (Primary)
E15
Main Transformer (Primary)
E16
Main Transformer (Secondary)
E17
(-) Output
E18
(+) Output
E19
Main Transformer (Secondary)
5.07 Right Side Center Chassis
Parts Replacement
NOTE
Refer to Section 6.06 for parts list and overall detail drawing.
A. Pilot/Output PC Board Assembly
Replacement
1. Remove the Right Side Panel per Section 5.04-A.
4. Disconnect the wiring from wire lug connections
on the Capacitor PC Board at E25 (+) and E26 (-)
terminals.
NOTES
Before removing any connection mark each wire
with the connection designation to ensure that
wires go to the proper terminals when reassembling.
Also note the routing of wires and make sure the
wires are put back in the same place when reassembling the unit.
5. Remove the two screws securing the Heatsink
Mounting Bracket to the chassis.
6. To remove the Mounting Bracket lift up on the
top FET/Heatsink Assembly and push down on
the bottom FET/Heatsink Assembly in the middle
where the two FET/Heatsink Assemblies come
together.
2. Mark all wirings/connections, then disconnect all
the wiring connections to the Pilot/Output PC
Board Assembly.
7. Slide the FET/Heatsink Assembly out and up to
remove the FET/Heatsink Assembly from the
unit.
3. Remove the four screws and washers securing the PC
Board to the standoffs.
4. Install the replacement Pilot/Output PC Board Assembly by reversing the above procedure. Refer to Appendix 6 for wiring connection diagram.
NOTE
FET/Heatsink Assemblies must be replaced in
pairs per the following illustration.
Manual 0-2697
5-7
REPLACEMENT PROCEDURES
B. Coolant Motor Relay (MC1) Replacement
1. Remove the Right Side Panel per Section 5.04-A.
E. Capacitive Discharge (CD) PC Board
Assembly Replacement
1. Remove the Right Side Panel per Section 5.04-A.
NOTES
NOTES
Before removing any connection mark each wire
with the connection designation. When reassembling this makes sure the wires go to the proper
terminals.
Before removing any connection, mark each wire
with the connection designation. When reassembling this makes sure the wires go to the proper
terminals.
Note the routing of wires and make sure the wires
are put back in the same place when reassembling
the unit.
Note the routing of wires and make sure the wires
are put back in the same place when reassembling
the unit.
2. Mark all wirings/connections then disconnect all
the wiring connections to the Relay Assembly.
2. Disconnect all the wiring connections to the CD
PC Board Assembly.
3. Remove the two screws securing the Relay Assembly to the Reservoir Panel.
3. Remove the four screws and washers securing the
PC Board to the standoffs.
4. Install the replacement Relay Assembly by reversing the above procedure.
4. Install the replacement CD PC Board Assembly
by reversing the above procedure.
C. Pilot Resistor (R1 & R2) Replacement
NOTE
F. Coolant Filter Replacement
1. Remove Right Side Panel per Section 5.04-A.
This unit has two Pilot Resistors. The replacement
instructions are the same for both.
2. Remove the two coolant hose connections to the Filter
Assembly.
1. Remove the Right Side Panel per Section 5.04-A.
NOTE
2. Remove all wiring connections to the Pilot/Output PC Board Assembly, noting the location of
each.
Some residual coolant may drain from the In-Line
Filter. It is recommended that a bucket, rag or towels be placed below the hose prior to removing.
3. Remove two nuts securing Pilot Resistor to Pilot
Panel.
3. Remove the two elbow fittings on each side of the
Coolant Filter Assembly and remove the damaged
Coolant Filter Assembly from the bracket.
4. Remove Pilot Resistor from studs.
5. Install replacement Resistor by reversing the
above procedure.
4. Clean the old thread sealer from the threads of
the elbow fittings.
D. Pilot Inductor (L3) Replacement
5. Apply a thin coating of liquid teflon thread sealer
to the threads of the elbow fittings.
1. Remove the Right Side Panel per Section 5.04-A.
6. Place the replacement Coolant Filter Assembly in
the bracket with the arrow pointing to the left and
reinstall the two elbow fittings.
2. Remove all wire connections to the Pilot Inductor, noting the location of each.
3. Remove four nuts securing Pilot Inductor to the
Pilot Panel and remove Pilot Inductor from unit.
7. Reconnect the two coolant hoses to the Coolant Filter
Assembly making sure that the hose to the Pump Assembly is on the output of the Coolant Filter Assembly).
4. Install replacement Pilot Inductor by reversing the
above steps.
8. Install Right Side Panel.
REPLACEMENT PROCEDURES
5-8
Manual 0-2697
12. Reinstall the replacement Coolant Reservoir by reversing the above steps, keeping in mind the following:
G. Coolant Reservoir Replacement
CAUTION
• Use thread sealant on all fittings when reinstalling.
• Refill the Coolant Reservoir with the coolant removed or fresh Thermal Arc Torch Coolant.
Handle and dispose of the used coolant per recommended procedures.
13. Place the Deionizer Basket and Bag into the Coolant Reservoir filler hole and install the Coolant Reservoir Cap.
NOTE
The Coolant Reservoir is removed by removing
the rear panel.
H. In-Line Coolant Filter Assembly
Replacement
1. Remove the Left and Right Side Panels per Section
5.04-A.
1. Remove the Right Side Panel per Section 5.04-A.
2. Drain the coolant from the Coolant Reservoir as follows:
CAUTION
a. Disconnect the Coolant Supply Hose input connection at the Coolant Filter Assembly. The hose
goes from the Coolant Filter Assembly to the bottom of the reservoir.
Handle and dispose of the used coolant per recommended procedures.
2. Partially drain the coolant from the Coolant Reservoir as follows:
b. Place the end of the hose into a container to catch
the coolant as it flows from the reservoir.
a. Disconnect the Reservoir to Coolant Filter Assembly hose at the Coolant Filter Assembly.
NOTE
b. Place the end of the hose into a container to
catch the coolant as it flows from the reservoir. Only enough needs to be removed so
that the level is below the In-Line Filter/Flow
Switch Assembly hole located on the end of
the reservoir.
Do Not run the pump as the coolant will gravity
feed from the reservoir.
c. Remove the Coolant Reservoir Cap then remove
the Deionizer Basket and Deionizer Bag from the
Coolant Reservoir filler hole.
NOTE
3. Disconnect the Coolant Supply Hose output connection from the bottom of the reservoir.
Do Not run the pump as the coolant will gravity
feed from the reservoir.
4. Disconnect the In-Line Filter Assembly where it connects to the reservoir.
3. Remove the hose connected to the bottom of the
In-Line Coolant Filter Assembly.
NOTE
NOTE
Some residual coolant may drain from the In-Line
Filter. It is recommended that a bucket, rag or towels be placed below the hose prior to removing.
Some residual coolant will drain from the In-Line
Filter. It is recommended that a bucket, rag or towels be placed below the hose prior to removing.
5. Disconnect two air lines connected to the two solenoid assemblies.
4. Remove bowl on In-Line Coolant Filter Assembly.
6. Remove the two bottom screws on Rear Panel.
5. Remove filter body from Flow Switch.
7. Remove the two nuts and washers on the inside of rear
panel connecting the panel to the center chassis.
6. Remove fittings from filter body.
7. Install the replacement In-Line Coolant Filter Assembly by reversing the above steps.
8. Remove the screw located in the center of the rear panel
which secures the rear panel to the reservoir panel.
NOTE
9. Carefully slide the rear panel out and away from the unit.
Use thread sealant on all the pipe threads when
reinstalling.
10. Remove the four nuts and washers (two top and two
bottom) securing the coolant tank to the reservoir panel.
8. Refill the Coolant Reservoir with the coolant removed
or add fresh Thermal Arc Torch Coolant.
11. Remove the coolant reservoir from the rear panel.
Manual 0-2697
5-9
REPLACEMENT PROCEDURES
I.
Flow Switch (FS1) Assembly Replacement
J. Output Inductor (L1 & L2) Assembly
Replacement
1. Remove the Right Side Panel per Section 5.04-A.
NOTES
CAUTION
There are two Output Inductors in this unit. Replacement instructions are the same for both.
Handle and dispose of the used coolant per recommended procedures.
2. Partially drain the coolant from the Coolant Reservoir
until the coolant level is below where the Flow Switch
connects to the Reservoir. Drain coolant as follows:
The Output Inductor(s) are located behind the reservoir panel. To gain access to the Output
Inductor(s), the rear panel of the unit is removed,
then the internal reservoir panel is disengaged and
moved out of the way.
a. Disconnect the Reservoir to Coolant Filter Assembly hose at the Coolant Filter Assembly.
1. Remove the Left and Right Side Panels per Section 5.04-A.
b. Place the end of the hose into a container to catch
the coolant as it flows from the reservoir. Drain
enough coolant so that the coolant level is below
the Flow Switch Assembly connection to the reservoir tank.
2. Drain the coolant from the Coolant Reservoir as
follows:
NOTE
Do Not run the pump as the coolant will gravity
feed from the reservoir.
3. Detach red wires at top end of Flow Switch where
they connect to wire harness.
4. Disconnect In-Line Coolant Filter from the bottom of Flow Switch Assembly.
NOTE
Some residual coolant will drain from the In-Line
Coolant Filter. It is recommended that a rag or
towels be placed below the hose prior to removing.
b. Disconnect the Coolant Supply Hose input
connection at the Coolant Filter Assembly. The
hose goes from the Coolant Filter Assembly
to the bottom of the reservoir.
c. Place the end of the hose into a container to
catch the coolant as it flows from the reservoir.
NOTE
Do Not run the pump as the coolant will gravity
feed from the reservoir.
3. Disconnect the Coolant Supply Hose output connection from the bottom of the reservoir.
5. Remove fitting from bottom end of Flow Switch
Assembly.
6. Disconnect Flow Switch from Reservoir and remove Switch from unit.
7. Install the replacement Flow Switch Assembly by
reversing the above steps, keeping in mind the
following:
a. The Flow Switch Assembly should be installed
at a slight angle to allow room for hose attachment with the filter pointing away from the
tank.
b. Use thread sealant on all the pipe threads when
reinstalling.
8. Refill the Coolant Reservoir to the full level (refer to
label on coolant tank) with either the coolant that was
removed or add fresh Thermal Arc Torch Coolant.
REPLACEMENT PROCEDURES
a. Remove Reservoir Cap from Reservoir.
5-10
4. Disconnect the In-Line Filter Assembly where it
connects to the reservoir.
NOTE
Some residual coolant may drain from the In-Line
Filter. It is recommended that a rag or towels be
placed below the hose prior to removing.
5. Disconnect two air lines where they connect to the two
solenoid assemblies.
6. Remove the two bottom screws on rear panel.
7. Remove the two nuts and washers on the inside of rear
panel connecting the panel to the center chassis.
8. Remove the rear panel from the unit by removing the
screw located in the center of the rear panel which
secures the rear panel to the reservoir panel.
Manual 0-2697
9. Carefully slide the rear panel out and away from the
unit.
K. Main Transformer (T1 & T2) Assembly
Replacement
10. Locate the two nuts on the base which secure the reservoir panel to the base, then remove nuts.
NOTES
There are two Main Transformers in this unit. Replacement instructions are the same for both.
NOTE
It may be necessary to disconnect some wiring in
order to have enough room to work. Note wire connections so that wires can be reconnected again
properly.
The Main Transformer(s) are located behind the
Reservoir Panel. In order to gain access to the
Output Inductor(s), the Rear Panel of the unit must
be removed and the internal Reservoir Panel disengaged and moved out of the way.
11. Slide reservoir panel up and out of the 'T' slots on
the center chassis and move panel to provide access to main transformers.
1. Remove the Left and Right Side Panels per Section
5.04-A.
12. Complete the following:
2. Drain the coolant from the Coolant Reservoir as follows:
a. Disconnect single leg orange wire from E17
on the FET/Heatsink Assembly and slide wire
back through adjacent bushing hole in center
chassis.
a. Remove Reservoir Cap from Reservoir.
b. Disconnect orange wire at E3 on Pilot Output
Board.
b. Disconnect the Coolant Supply Hose input connection at the Coolant Filter Assembly. The hose
goes from the Coolant Filter Assembly to the bottom of the Reservoir.
13. Note orientation of Inductor, then remove four
lock nuts securing Transformer to center chassis.
c. Place the end of the hose into a container to catch
the coolant as it flows from the reservoir.
14. Install the replacement Output Inductor by reversing the above procedure, keeping in mind the following:
NOTE
Do Not run the pump as the coolant will gravity
feed from the reservoir.
• Reservoir Panel must seat in corresponding
center chassis slots.
3. Disconnect the Coolant Supply Hose output connection from the bottom of the Reservoir.
• The four screws securing the Inductor mounting
plate to the center chassis should have a maximum
of 2 to 5 threads protruding through the left side of
the chassis.
4. Disconnect the In-Line Filter Assembly where it connects to the Reservoir.
NOTE
Some residual coolant may drain from the In-Line
Filter. It is recommended that a bucket, rag or towels be placed below the hose prior to removing.
5. Disconnect two air lines where they connect to
the two Solenoid assemblies.
6. Remove the Rear Panel per procedures in Section
5.09-B.
7. Locate the two nuts on the base which secure the Reservoir Panel to the base.
8. Remove nuts.
NOTE
It may be necessary to disconnect some wiring in
order to have enough room to work. Note wire connections so that wires can be reconnected again
properly.
Manual 0-2697
5-11
REPLACEMENT PROCEDURES
9. Slide reservoir panel up and out of the 'T' slots on the
center chassis and move panel to provide access to
main transformers.
L. Pilot Panel Fan (M1 - M4) Replacement
10. Carefully remove all wire connections to the FET PCB
Assembly noting the location of each per the following chart:
There are four Fans mounted to the Pilot Fan
Panel. Replacement instructions are the same for
all Fans.
NOTE
1. Remove Front Panel per Section 5.04-E.
Cable #
14A
15A
16A
19A
14B
15B
16B
19B
FET PCB
Connection
E14
E15
E16
E19
E14
E15
E16
E19
2. Remove the two screws securing the Fan to the two
tabs on the Pilot Fan Panel.
3. Turn the fan sideways and pull gently out of unit to
where the wires can be disconnected.
4. Carefully note wiring connections, then disconnect
wires.
5. Install replacement Fan(s) by reversing the above
steps, noting the following:
a. Piggyback tabs face outside.
NOTES
b. Label faces inside unit.
Make sure white #19 wires are looped around and
connected from the right side.
Transformer leads are marked 'A' & 'B'. Group
'A' is wired to the top heatsink and group 'B' is
wired to the bottom heatsink. Wires are placed belly
up."
AIR
OW
FL
Air Flow/Rotation
Label Molded Into
Fan Housing
T
TA
O
R
IO
11. Note orientation of Main Transformer Assembly,
then remove four lock nuts securing Transformer
to the center chassis.
N
c. Orient Fan so that Air Flow/Rotation Label
molded into the Fan Housing is positioned as
shown in the following illustration.
12. Install the replacement Transformer Assembly by reversing the above procedure, keeping in mind the following:
• Reservoir Panel must seat in corresponding center
chassis slots.
• The four screws securing the output inductor
mounting plate to the center chassis should have a
maximum of 2 to 5 threads protruding through the
left side of the chassis.
Air Flow/Rotation
Label Direction
Air Flow
Arrow
Direction
A-02290
REPLACEMENT PROCEDURES
5-12
Manual 0-2697
M. Current Sense PC Board Assembly
Replacement
1. Remove the Work Cable per Section 5.04-C.
5.08 Base Parts Replacement
A. Wheel/Axle Assembly Replacement
• Wheel Replacement
2. Disconnect the ribbon cable from the Current Sensor at J17 on the Logic PC Board.
NOTE
3. Remove the Sensor by prying off standoffs at the
rear of the Bulkhead, behind the Work Cable
Strain Relief.
Both Wheels are removed and replaced in the same
manner.
1. Raise the unit off the floor far enough for the weight
of the unit to be removed from the axle and wheels.
4. Install the replacement Current Sensor PC Board
by reversing the above procedure.
2. For the wheel to be replaced, remove retaining ring,
washer, wheel and second washer from end of axle.
N. CD Coil (T4) Assembly Replacement
3. Install the replacement wheel(s) by reversing above
procedure.
NOTE
Prior to removal, note the location and orientation
of the CD Coil Assembly and all its connections.
• Axle Replacement
1. Raise the unit off the floor far enough for the
weight of the unit to be removed from the axle
and wheels.
1. Remove the Left and Right Side Panels per Section 5.04-A.
2. Remove the Top Panel per Section 5.04-B.
2. Remove both wheels from the axle.
3. Disconnect the coolant hose from the fitting at the end
of the bulkhead adapter.
3. Slide the faulty axle out of base.
4. Install the replacement axle by reversing above
procedure.
4. Drain coolant from hose into bucket.
5. Remove the first nut and washer from the bulkhead
adapter.
6. Disconnect CD Coil Leads at E1 & E2 on the CD PC
Board.
7. Disconnect stiff CD Coil Wire from PS(-) on Pilot Output Board.
Screws
8. Remove two screws in Ferrite U-Core attaching it to
the bulkhead chassis and remove CD Coil Assembly
from unit.
Axle
A-02307
9. Install the replacement CD Coil Assembly by reversing
the above procedure.
Washer
Wheel
Retaining
Ring
Manual 0-2697
5-13
REPLACEMENT PROCEDURES
5. Install the replacement Main Contactor Assembly by
reversing the above steps, connecting wires as follows:
B. Support Leg(s) Assembly Replacement
NOTE
Both support leg assemblies are removed and replaced in a similar manner.
a. Connect ground wire as shown.
1. Raise the unit off the floor far enough for the
weight of the unit to be removed from the support legs.
2-Brass
Nuts
Input
Board
Ground
Side
Panel
Ground
2. Remove two screws securing support leg to front of
base.
3. Install replacement support leg by reversing above step.
C. Auxilliary Transformer (T3) Assembly
Replacement
3-Star
Washers
A-02291
Main
Harness
Ground
NOTE
All replacement Auxilliary Transformers Assemblies include two fuses.
1. Remove the Right Side Panel per Section 5.04-A.
2. Note orientation of all the wires connected to the
Auxilliary Transformer Assembly.
3. Disconnect wires.
b. Attach main harness wires #55 and #59 to the
coil of the Contactor.
Main Contactor
(MC1)
L3
L2
L1
4. Remove the four flat washers and nuts securing
the Auxilliary Transformer to the four base studs.
Coil
Wire #55
5. Remove Transformer from unit.
6. Install replacement Transformer by reversing the
steps above.
D. Main Contactor (W) Assembly Replacement
NOTE
The Main Contactor was located in the Base on
earlier units and on the Center Chassis for current
units.
A-01195
1. Remove the Left Side Panel per Section 5.04-A.
2. Note orientation of the Main Contactor and location of all wires and cables connected to the
Contactor Assembly.
Coil
Wire #59
c. Attach the main harness wires #4 & #5 to the
inner prong of L1 & L2 respectively of the main
contactor.
d. Connect cables 1, 2, and 3 to T1, T2, and T3 respectively.
3. Disconnect wires and cables at Main Contactor.
4. Remove the two nuts securing the Contactor Assembly to the two mounting studs in the unit.
REPLACEMENT PROCEDURES
5-14
Manual 0-2697
E. Motor (M5) / Fan / Pump Replacement
F. Fan Assembly Only Replacement
The simplest way to replace the Motor is to remove the Motor,
Fan and Pump together, then replace the Motor. The procedure
below describes how to remove the Motor/Fan Pump Assembly to replace the Motor. To replace the Fan, continue with the
procedures outlined in Section 5.08-F, Fan Assembly Only Replacement. To replace the Pump, follow the procedures outlined in Section 5.08-G, Pump Assembly Replacement.
1. Remove Motor/Fan/PumpAssembly from unit per procedure in 5.09-E.
2. Loosen the fan locking screw securing the Fan to the
Motor Assembly shaft and remove the Fan.
3. Install replacement Fan by reversing the above steps,
noting the following:
1. Remove the Right Panel per Section 5.04-A.
a. The fan locking screw is facing the motor and
aligned with flat of shaft. The motor assembly shaft must be flush with the front part of
the Fan Bushing.
2. Disconnect the following:
NOTE
Coolant may drain from the hoses. It is recommended that a bucket, rags or towels be placed below the hose prior to removing.
b. Apply loctite to the fan screw before tightening.
G. Pump Assembly Replacement
a. Radiator to In-Line Filter Hose - disconnect
at Filter.
1. Remove the Motor/Fan/PumpAssembly per procedure
in 5.09-E.
b. Radiator to Torch Hose - disconnect at Bulkhead.
2. Loosen the Pump Clamp securing the Pump Assembly
to the Motor Assembly.
c. Pump to Coolant Filter Hose - disconnect at
Pump.
3. Note the orientation of the Pump Assembly to the Motor
Assembly.
d. Pump to Torch Hose - disconnect at Bulkhead.
4. Pull the Pump Assembly from the Motor Assembly.
e. Remove tie wraps as necessary.
5. Disassemble the Pump Assembly in the sequence
shown below, beginning with #1:
3. Note connection of all wires to Motor then disconnect wires.
4. Remove four nuts and washers securing the Motor Mount to the base, and remove Motor/Pump/
Fan Assembly.
To
Coolant
Filter
5. Replace Fan and Pump per procedures in Sections
5.09-F and 5.09-G respectively, if required.
1
To
Bulkhead
6. Install the replacement Motor with pump and fan
by reversing the above procedure (see NOTE).
8
Pump
NOTE
2
Before installing the replacement Motor, check that
the internal wiring of the Motor is set for the proper
input voltage per the information on the Motor
nameplate.
7
5
3
6
4
A-02286
Manual 0-2697
5-15
REPLACEMENT PROCEDURES
6. Install the replacement Pump Assembly by reversing
the above steps, noting the following:
5.09 Rear Panel Parts Replacement
NOTE
a. Proper orientation of the Pump Assembly to the
Motor Assembly.
b. Install check valve with the flow marking towards
the bottom (as shown above).
Refer to Section 6.08 for parts list and overall detail drawing.
A. Handle Replacement
c. Use thread sealant on all pipe threads (Loctite thread
sealant #565, or equivalent).
1. Remove the four hex head screws securing the
handle to the Rear Panel of the unit.
7. Refill Coolant Reservoir.
2. Remove the Handle from the Rear Panel.
8. Connect primary power and turn on unit.
3. To install the replacement Handle, reverse the above
procedure.
H. Radiator Assembly Replacement
B. Rear Panel Replacement
NOTE
1. Remove the Left and Right Side Panels per Section
5.04-A.
The Front Panel, Right Side Panel and Motor/
Fan/Pump Assembly must be removed first in order to remove the Radiator.
2. Remove the Top Panel per Section 5.04-B.
1. Remove the Right Side Panel per Section 5.04-A.
2. Remove the Front Panel per Section 5.04-E.
3. Remove the Motor/Fan/Pump Assembly per Section 5.08-E.
a. Disconnect the air line hose connected to the solenoid/pressure switch assembly
4. Carefully disconnect Thermal Switch (solid state)
near the inlet port and slide it out through hole in
mounting bracket. Remove ties as required.
b. Disconnect the air line hose connected to the solenoid assembly.
5. Remove (6) screws securing Radiator to frame.
6. Install the replacement Radiator by reversing the
above procedure.
I.
3. Remove the two Regulators on the Rear Panel by completing the following:
Thermal Switch (TS1) Replacement
1. Remove the Right Side Panel per Section 5.04-A.
2. Locate the Radiator and carefully disconnect the Thermostat Switch (solid state) near the inlet port and slide
out through hole in mounting bracket. Remove ties as
required.
3. Install the replacement Thermal Switch by reversing
the above procedure..
c. Note the location of two blue wires connected to
the solenoid assembly (secondary) and four blue
wires connected to the solenoid/pressure switch
assembly (plasma).
d. Disconnect wires.
e. Note solenoid orientation then remove the solenoid assembly from the 2 inch long brass nipple
and set assembly aside.
f. Note solenoid/pressure switch orientation, then
remove the solenoid/pressure switch assembly from
the 2 inch brass nipple, and set aside.
g. Remove the four screws securing each regulator to
the rear panel and remove Regulators.
4. Remove reservoir cap from the reservoir.
5. Disconnect the following input power cable wires from
Main Contactor:
• L1, L2 & L3.
• Ground connection to base panel.
6. Remove strain relief from rear panel.
REPLACEMENT PROCEDURES
5-16
Manual 0-2697
7. Remove rear panel from unit by completing the following:
D. Solenoid Valve (SOL1 & SOL2)
Replacement
a. Remove the two screws on near bottom of rear panel
securing the panel to the base of the unit.
NOTE
There are two Solenoid Valve Assemblies in this
unit; one for plasma gas and one for secondary gas
(as labeled on rear panel). The Solenoid Assembly
for secondary gas has a Pressure Switch which must
be removed before the Solenoid can be removed. Following the instructions as they pertain to the Solenoid Valve being replaced.
b. Remove the two nuts and washers on the inside of
rear panel connecting the panel to the center chassis.
c. Remove screw located in the center of the rear panel
securing the rear panel to the frame.
d. Carefully lift the rear panel up, over the reservoir,
and away from the power supply.
1. Remove the Right Side Panel per Section 5.04-A.
8. To install replacement rear panel, reverse the above
procedure.
2. Locate the Solenoid Assembly to be replaced. Parts
are assembled as shown below.
C. Pressure Switch (PS1) Replacement
1. Remove the Right Side Panel per Section 5.04-A.
Secondary Gas
2. Disconnect the two wires connected to the Pressure
Switch Assembly (see Figure below).
A-02298
Blue
Wires
3. Remove the Pressure Switch Assembly from the T-fitting.
4. Install the replacement Pressure Switch Assembly by
reversing the above procedure, keeping in mind the
following:
Solenoid
Brass
Nipple
Brass
Nipple
Blue
Gas
Tubing Wires
"L" Fitting
• Apply pipe thread sealant to the fitting before reassembling.
Pressure
Switch
Gas Tubing
Plasma Gas
3. Note the location of all wires, then disconnect the following:
a. Disconnect the gas tubing at the solenoid or "L"
fitting.
b. Disconnect blue wires.
4. Disconnect the Pressure Switch from the Plasma Gas
"L" fitting, if applicable.
5. Note the orientation of the Solenoid Valve Assembly
then remove the Solenoid(s) from the two inch brass
regulator fitting(s).
6. Install the replacement Solenoid Valve Assembly by
reversing the above procedure.
Manual 0-2697
5-17
REPLACEMENT PROCEDURES
E. Air Line Regulator Bracket(s) Replacement
NOTE
5. Remove the Regulator from the 2 inch brass nipple
connected to the Solenoid Assembly.
6. Remove the elbow fitting from the old assembly.
There are two Air Line Regulator Brackets in this
unit and both are replaced using this same procedure.
1. Remove the nut securing the Air Line Regulator
to the mounting bracket.
2. Remove the four screws securing the Air Line
Regulator Bracket to the Rear Panel.
7. Install the replacement Air Line Regulator Assembly
by reversing the above procedure, keeping in mind the
following:
• Apply pipe thread sealant to the fitting before reassembling.
3. Remove bracket from unit.
4. Install the replacement Air Line Regulator Bracket
by reversing the above procedure.
F. Air Line Regulator(s) Replacement
NOTE
This unit has two Air Line Regulators - one for
plasma gas and one for secondary gas. This procedure applies to both Regulators.
1. Remove the Right Side Panel per Section 5.04-A.
2. Disconnect the gas input hose from the inert B fitting
input located on the right side of the Air Line Regulator
Assembly.
Gas Pressure
Regulator
Filter
Assemblies
Gas Input
Input Hoses
A-02327
3. Remove the four screws securing the Regulator
to the Rear Panel.
4. Pull the Air Line Regulator away from the Rear
Panel far enough to disconnect the plumbing joint
between the Reducer and Elbow Fitting.
REPLACEMENT PROCEDURES
5-18
Manual 0-2697
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts lists provide a breakdown of all replaceable
components. Parts Lists are organized as follows:
Section 6.03 Major External Replacement Parts
Section 6.04 Access Panel Replacement Parts
Section 6.05 Left Side Center Chassis Replacement
Parts
Section 6.06 Right Side Center Chassis Replacement
Parts
Section 6.07 Base Component Replacement Parts
Section 6.08 Rear Panel Replacement Parts
Section 6.09 Options and Accessories
NOTE
Parts listed without item numbers are not shown,
but may be ordered by the catalog number shown.
B. Returns
If a product must be returned for service, contact your
authorized distributor. Materials returned without proper
authorization will not be accepted.
C. Product Improvements
Improvements to the product since release is denoted by
a revision letter(s) located on the data tag of the unit.
There are old style and new style data tags that may be
encounted. The old style data tag has the revision letter(s)
at the end of the serial number. The new style data tag
has the revision letter(s) in an area marked 'Rev'. The
parts lists may include references to the revision letter(s)
for parts that are different between revisions.
6.02 Ordering Information
Order replacement parts by catalog number and complete
description of the part or assembly, as listed in the parts
list for each type item. Also include the model and serial
number of the torch. Address all inquiries to your authorized distributor.
Manual 0-2697
6-1
PARTS LISTS
6.03 Major External Replacement Parts
Item #
Qty
1
1
Right Side Panel With Labels
9-7819
2
1
Left Side Panel With Labels
9-7818
3
1
Front Panel With Labels
9-7816
4
1
Rear Panel
9-7820
5
1
Top Panel
6
1
Description
Catalog #
Top Panel for Units Revision I or earlier
9-7817
Top Panel for Units Revision J or later
9-7797
Access Panel With Labels & Screws
Access Panel for Units Revision AU or earlier
9-7821
Access Panel for Units Revision AV or later
9-9034
7
1
Cable, Work, 20 ft (6.1 m) #4 AWG With Clamp
9-2783
8
1
Boot, Rubber
9-4210
The following is not shown:
1
Torch Coolant – 1 Gallon (3.87 Liters)
Extra-CoolTM Coolant for Ambient Temperatures to +10°F (-12°C)
Ultra-CoolTM Coolant Ambient Temperatures to -27°F (-33°C)
7-3580
7-3581
5
4
1
6
7
8
2
A-03056
3
PARTS LISTS
6-2
Manual 0-2697
6.04 Access Panel Replacement Parts
Item #
Qty
1
1
Description
Ref
Catalog #
Assembly, POT/LED PCB
Pot/LED Assembly for Units Revision H or earlier
9-7014
Pot/LED Assembly for Units Revision I or later
9-8004
2
1
RUN/SET Switch, SPST
SW2
9-1042
3
1
ON/OFF Switch, DPST
SW1
8-3258
4
1
Knob, CURRENT Control With Foam Seal
9-8007
5
2
DZUS Stud
9-4346
6
2
DZUS Retaining Ring
9-4347
7
1
Pot Protection Kit includes:
7-7575
8
2
Handles
2
Screws
2
Star Washers
1
STANDARD/LATCH Switch (Units Revision AV or Later)
SW3
9-1042
3
4
7
8
2
5
7
5
A-02256
6
1
Manual 0-2697
6-3
PARTS LISTS
6.05 Left Side Center Chassis Replacement Parts
Item #
Qty
Description
Ref
Catalog #
1
1
Fuse Block,
2
1
Fuse, 5 AMP, 600V, Delay
3
1
Input PC Board Assembly
9-7813
4
1
Bridge Rectifier Assembly, 110A 3PH
9-7824
1
Bridge Rectifier, 110A 3PH
9-7800
1
Thermal Pad, QIII, Input Module
9-5562
F1
10-2274
5
1
Thermostat, Closes @ 80° C Rising
TS2
9-7895
6
1
Contactor, 4 Pole, 40 FLA, 120 VAC (In-Rush Contactor)
INR
9-7507
7
1
Logic PC Board Assembly
9-7812
8
2
Gate Drive PC Board Assembly
9-7811
9
1
FET/Heatsink Assembly Kit, Includes:
9-7015
2
10
1
FET/Heatsink Assembly
Main Contactor (Location on current units)
W
9-1244
Refer to Section 6.07 for location on earlier units
The following parts are not shown:
PARTS LISTS
1
Cable Assembly, 10 Circuit Ribbon, 15 inches (381 mm) Long
9-5922
1
Cable Assembly, 3 Circuit
9-7509
1
Cable Assembly, 20 Circuit Ribbon, 20 inches (508 mm) Long
9-7804
6-4
Manual 0-2697
7
1
2
5
6
4
3
10
8
9
9
Manual 0-2697
A-02274
6-5
PARTS LISTS
6.06 Right Side Center Chassis Replacement Parts
Item #
Qty
Description
Ref
Catalog #
1
1
Pilot/Output PC Board Assembly
2
1
Relay, DPST, 25A Max, 120 VAC (Coolant Motor Relay)
MC1
8-3390
3
2
Resistor
R1,R2
9-5843
4
1
Inductor, Pilot
L3
9-7801
5
1
CD PC Board Assembly
9-7814
6
1
Coolant Filter
8-4276
7
1
Coolant Reservoir
9-5948
8
1
Filter, In-Line, Female
8-3460
9
1
Flow Switch Assembly, 0.2 GPM
10
2
Main Transformer
11
1
Output Inductor Assembly
12
4
Fan, 115VAC, 50/60Hz, 95/115CFM W/0.187 Tabs
13
1
Assembly, Current Sense PC Board
9-7602
14
1
Hose, Filter To Pump
9-7805
15
1
Hose, Radiator To Small Filter
9-7807
16
1
Hose, Reservoir To Filter
9-7808
17
1
Assembly, CD Coil
18
1
Deionizer Bag
8-3312
19
1
Deionizer Basket
8-4410
20
1
Cap, Coolant Tank
8-5142
21
1
Output Inductor Assembly
1
Field Update Kit (for Units before Rev AZ)
1
Shield Return Capacitor Assembly
1
Pilot Panel Ground Strap
9-7809
FS1
9-5937
T1, T2
9-7810
L1
9-7815
M1-M4
8-3209
T4
L2
9-7825
9-7872
Not Shown:
PARTS LISTS
6-6
9-8651
Manual 0-2697
6
5
20
16
14
18
10
19
11
21
10
7
2
17
9
3
8
15
13
A-02275
12
4
NOTE:
Parts may differ slightly from illustration
1
Manual 0-2697
6-7
PARTS LISTS
6.07 Base Replacement Parts
Item #
Qty
1
2
Wheel
8-5579
2
1
Axle
9-7891
3
2
Support Leg
9-7892
4
1
Transformer, Auxiliary (220,395,460)
2
5
1
Description
Ref
T3
Fuse, 5A, 250V Delay MDL-5 (in Torch Spare Parts Kit)
Main Contactor (Location on earlier units)
Catalog #
9-7802
9-8109
W
9-1244
Refer to Section 6.05 for location on current units
6
1
Fan, Medium Pressure, 8 inch (203 mm) Diameter
7
1
Motor, 1/3 HP, 1425/1725 RPM, 115/230 V, 50/60 Hz
8
1
Pump
9-6164
9
1
Radiator Assembly (Includes 6 Grommets)
9-5941
10
1
Hose, Torch Disconnect To Radiator
9-7806
11
2
Foot, Rubber
9-7894
12
1
#6 JIC-3/8 NPT STR Adapter
8-0348
13
1
#6 JIC-3/8 NPT x 90° Adapter
9-3077
14
1
3/8 NPT Close Nipple
9-2384
15
1
3/8 NPT Hex Head Plug
9-4583
16
1
3/8 NPT Female Tee
9-2385
17
1
3/8 NPT Street Elbow
9-2365
18
1
3/8 NPT Close Nipple
9-2384
19
1
Valve, Check 3/8 NPT Female, Brass
9-1402
20
1
Thermal Switch
21
1
Clamp, Pump V-Brand
PARTS LISTS
9-7893
M5
TS1
9-5932A
9-5967
9-5942
6-8
Manual 0-2697
7
21
12
8
13
14
6
19
10
18
9
15
16
17
20
5
4
2
23x4274
3
1
11
A-02278
Manual 0-2697
6-9
PARTS LISTS
6.08 Rear Panel Replacement Parts
Item #
Qty
Description
Ref
1
1
Handle With Screws
2
1
Pressure Switch, 35 psi (2.4 bar)
3
2
Valve, Solenoid 1/8 NPT
4
2
Air Regulator/Filter Assembly
Catalog #
9-7822
PS1
9-1044
SOL1, SOL2
8-3370
Air Line Regulator
9-7514
Pressure Gauge
9-1045
Panel Mounting Nut
9-5804
Bracket, Regulator Mounting
9-7589
5
2
Hose
9-3743
6
1
1/4 NPT Female Tee
9-2034
7
1
Strain Relief
9-3164
8
1
One Touch, 90°, 1/8 NPT
9-2391
9
2
Fitting 1/8 NPT x 2' Long Nipple, Brass
9-7524
10
2
1/4 - 1/8 NPT Reducer
9-2023
11
2
1/4 NPT Street Elbow
9-2184
12
2
Nipple, Close, 1/4 NPT - 1/4 NPT
9-2186
13
2
1/4 NPT Female Elbow
9-4595
14
1
Fitting 1/8 NPT x 1/4 Tube Str
8-3360
15
2
Fitting, Adapter, 1/4NPT - Inert B, Right Hand
8-0330
PARTS LISTS
6-10
Manual 0-2697
1
2
3
9
8
10
3
14
9
11
10
15
11
12
4
13
15
4
5
5
A-02257
6
7
Manual 0-2697
6-11
PARTS LISTS
6.09 Options and Accessories
Qty
1
Description
Catalog #
1
1
1
Two Stage Air Line Filter Kit
Replacement Elements
First Stage
Second Stage
Mounting Bracket
7-7502
1
1
CNC Interface Control Cable - Used With Shielded PCM Machine Torch
25 ft (7.6 m)
50 ft (15.2 m)
8-5557
8-5558
1
575V Transformer Module
9-7700
1
1
Primary Input Power Cable, 10 ft. (3.05 m)
230VAC, 2AWG, 4 COND, 600V
460VAC, 6AWG, 4 COND, 600V
9-7697
9-7696
1
"Y" Hose Assembly Kit
9-7827
1
Locking Caster Kit (2 Casters)
9-7868
1
Remote Pendant Control 20ft (6.1 m) - Used With Unshielded
7-3460
9-1021
9-1022
9-7535
PCM Machine Torch
PARTS LISTS
6-12
Manual 0-2697
APPENDIX 1: INPUT WIRING REQUIREMENTS
Input
Power Input
Current
Suggested Sizes (See Notes)
Voltage
Freq.
3-Ph
3-Ph
Fuse (Amps)
Wire (AWG)
Wire (Canada)
(Volts)
208
220
230
240
380
415
460
(Hz)
50/60
50/60
50/60
50/60
50/60
50/60
50/60
(kVA)
28.1
28.6
29.5
29.9
29.0
29.5
29.5
(Amps)
78
75
74
72
44
41
37
3-Ph
100
100
100
90
60
60
50
3-Ph
2
2
2
2
6
6
6
3-Ph
2
2
2
2
6
6
6
575
Requires Transformer Module
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electrical Code
NOTES
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations
refer to local or national codes.
Cable conductor temperature used is 167° F (75° C).
An energy limiting fuse UL Class RK-1 (examples: BUSS LPS/LPN-RK or Gould-Shawmut AZK-A6K) should be
used to minimize damage to Plasma Cutting, Welding or power distribution equipment.
NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.
Manual 0-2697
A-1
APPENDIX
APPENDIX 2: SEQUENCE OF OPERATION (BLOCK
DIAGRAM)
ACTION
ACTION
ACTION
ACTION
Close external
disconnect switch.
ON/OFF switch
to ON.
RUN/SET switch
to SET.
RUN/SET switch
to RUN.
RESULT
RESULT
RESULT
RESULT
Power to system.
AC indicator blinks for 8
seconds then steady on.
Fans on.
Power circuit ready.
Gas solenoid open,
gas flows to set pressure.
GAS indicator on.
Gas flow stops.
GAS indicator off.
ACTION
STANDARD/LATCH
switch to STANDARD
ACTION
STANDARD/LATCH
switch to LATCH
ACTION
Torch moved away
from work (while
still activated).
RESULT
ACTION
Main arc stops.
Pilot arc automatically
restarts.
Protect eyes and
activate torch
PILOT ARC
RESULT
Gas flows (2 seconds).
After gas pre-flow:
DC indicator on.
Pilot arc established
ACTION
Torch moved within
transfer distance of workpiece.
RESULT
Main arc transfer.
Pilot arc off.
ACTION
Torch deactivated (by torch switch
release or by remote device).
ACTION
Torch Switch released.
RESULT
RESULT
Transfer will continue
until torch is removed
from workpiece.
Main arc stops.
(Power supply enable signal removed.)
Gas flows (15 seconds)
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
ACTION
ON/OFF switch
to OFF
Gas solenoid closes, gas flow stops.
GAS indicator off.
Open external
disconnect.
RESULT
RESULT
All indicators off.
Power supply fans off.
No power to system.
A-03050
APPENDIX
A-2
Manual 0-2697
APPENDIX 3: POT/LED PC BOARD LAYOUT
J14
D4
D5
D7
D6
A-01206
Pot/LED PC Board Signals
J14-1
J14-2
J14-3
J14-4
J14-5
J14-6
J14-7
J14-8
+10 vdc from Logic PC Board (J3-7) - Potentiometer High
Current Control to Logic PC Board (J3-8) - Potentiometer Wiper
Return for Current Control from Logic PC Board (J3-9) - Potentiometer Low
+12 vdc from Logic PC Board (J3-10)
Signal for AC OK Indicator to Logic PC Board (J3-11)
Signal for GAS Indicator to Logic PC Board (J3-12)
Signal for TEMP Indicator to Logic PC Board (J3-13)
Signal for DC Indicator to Logic PC Board (J3-14)
D4
D5
D6
D7
Front Panel AC Indicator
Front Panel TEMP Indicator
Front Panel DC Indicator
Front Panel GAS Indicator
Manual 0-2697
A-3
APPENDIX
APPENDIX 4: LOGIC PC BOARD LAYOUT
1
J17
12
1
TP1 (Ground)
1
J96
4
J2
D65
12
2
1
J1
5
1
J3
8
J99
18
1
D47
2
1
D36
J4
20
Logic PC Board
A-02310
D31
24
D26
J5
D25
19
1
Logic PC Board Signals
J1-1
J1-2
J1-3
J1-4
J1-5
J1-6
36 VAC from Auxiliary Transformer
115 VAC from Auxiliary Transformer
Center Tap from Auxiliary Transformer
Not Used
36 VAC from Auxiliary Transformer
115 VAC Return from Auxiliary Transformer
J2-11
J2-12
J2-13
J2-14
J2-15
J2-16
Over Temp Sw. (Input Bridge, Pilot Bd, Radiator) 12V
Over Temp Sw. (Input Bridge, Pilot Bd, Radiator) Return
Not Used
Not Used
Not Used
Not Used
J2-1
J2-2
J2-3
J2-4
J2-5
J2-6
J2-7
J2-8
J2-9
J2-10
115 VAC Return to Main Contactor
115 VAC Return to Plasma Solenoid
Not Used
115 VAC to Main Contactor
Not Used
115 VAC to Secondary Solenoid
Not Used
Not Used
Pressure Switch +12 vdc Signal
Pressure Switch Return
J3-1
J3-2
J3-3
J3-4
J3-5
J3-6
J3-7
J3-8
J3-9
36 VAC to ON/OFF Switch
36 VAC from ON/OFF Switch
36 VAC to ON/OFF Switch
36 VAC from ON/OFF Switch
RUN/SET Switch on Front Panel +12V signal
RUN/SET Switch on Front Panel Return
Main Current Control Signal (High) +10 vdc
Main Current Control Pot (Wiper)
Main Current Control Pot (Low)
APPENDIX
A-4
Manual 0-2697
J3-10
J3-11
J3-12
J3-13
J3-14
J3-15
J3-16
+12 vdc
Active Low Signal for AC Indicator on Front Panel (J14-5)
Active Low Signal for GAS Indicator on Front Panel (J14-6)
Active Low Signal for TEMP Indicator on Front Panel (J14-7)
Active Low Signal for DC Indicator on Front Panel (J14-8)
Not Used
Not Used
J4-1
J4-2
J4-3
J4-4
J4-5
J4-6
J4-7
J4-8
J4-9
J4-10
J4-11
J4-12
J4-13
J4-14
J4-15
J4-16
J4-17
J4-18
J4-19
36 VAC (b) from Gate Driver PC Board (J9-1)
36 VAC (a) to Gate Drive PC Board (J9-2)
36 VAC (a) from Gate Drive PC Board (J9-3)
36 VAC (b) to Gate Drive PC Board (J9-4)
36 VAC CT Return/PC Board Common
Transfer Mod Enable Return
36 VAC CT Return/PC Board Common
Active Low Transfer Mod Enable Signal
Return for Temp Switch
Active Low Over Temp Signal
Return for Master Enable Signal
Active Low Master Enable Signal
Return for Pilot Enable
Active Low Pilot Enable Signal
Return for PSR Signal
Active Low PSR Signal
Return for Demand Signal
Demand Signal
Return for Demand Signal
J5-1
J5-2
J5-3
J5-4
J5-5
J5-6
J5-7
J5-8
J5-9
J5-10
J5-11
J5-12
J5-13
J5-14
J5-15
J5-16
J5-17
J5-18
J5-19
J5-20
J5-21
36 VAC (b) to CD PC Board
36 VAC CT Return to CD PC Board
36 VAC (a) to CD PC Board
Active Low CD Enable Signal
CD Enable Return
Active Low Pilot Signal to Pilot/Output Board
Pilot Signal Return
Active Low Torch Switch Signal
Torch Switch Return
Active Low Torch Sw Signal to LATCH Sw
Not Used
PS+
Not Used
Drag Sensing Signal Voltage (Tip Volts +)
Not Used
PS36 VAC (a) to Pilot Output Board
36 VAC (b) to Pilot Output Board
36 VAC CT Return to Pilot/Output Board (Opt Remote)
Active Low ENABLE Signal
Return for Optional Remote Enable Jumper
Manual 0-2697
A-5
J95-1
J95-2
Not Used
Not Used
J96-1
J96-2
J96-3
J96-4
115VAC to Fans M3 & M4
115VAC to Fans M1 & M2
115VAC Fan Rtn for M3 & M4
115VAC Fan Rtn for M1 & M2
J17-1
J17-2
J17-3
J17-4
J17-5
J17-6
J17-7
J17-8
J17-9
J17-10
J17-11
J17-12
Not Used
Not Used
115 VAC to Plasma Solenoid
115 VAC to Inrush Cont
115 VAC to Motor Cont
Not Used
115 VAC Return Sec. Solenoid
115 VAC Return Inrush Cont
115 VAC Return Motor Cont
Not Used
OK-To-Move (Isolated Contact Closure)
OK-To-Move (Isolated Contact Closure)
J99-1
J99-2
J99-3
J99-4
J99-5
J99-6
J99-7
J99-8
Active Low Coolant Flow Switch Signal
Not Used
Coolant Flow Switch Return
Not Used
Active Low Torch Sw Signal from LATCH Sw
Active Low CSR Signal From Current Sense Board
Return
+12 vdc
TP1
TP2
TP3
TP4
TP5
TP6
TP7
TP8
TP9
TP10
TP11
Logic Ground
+18 vdc - Unregulated
+18 vdc - Unregulated
+10 vdc
Demand Signal to Gate PC Board
+12 vdc
Drag CRT
(-) DC Sense
Active Low PSR Signal
Active Low CSR Signal
Current Control Demand (Pot Wiper)
D26
D25
D65
D47
D31
Torch Switch Enable Indicator
CD Enable Indicator
CSR Indicator
AC OK Indicator
Drag On Indicator
APPENDIX
APPENDIX 5: GATE DRIVE PC BOARD LAYOUT
J11
J9
TP16
TP15
TP3
J10
D4
TP1
TP4
TP5
TP11
TP6
TP12
J8
J7
TP2
TP13
TP8
D20
TP9
TP10
TP7
TP14
Gate Drive PC Board Signals
J7-1
J7-2
J7-3
J7-4
J7-5
J7-6
J7-7
J7-8
J7-9
J7-10
+12 vdc to FET PC Boards (J6-1)
Return for +12 vdc to FET PC Boards (J6-2)
PWM Output (A) to FET PC Boards (J6-3)
Gate Drive PC Board
PWM Return to FET PC Boards (J6-4)
Primary Current Sense from FET PC Boards (J6-5)
Primary Current Sense Return from FET PC Boards (J6-6)
Secondary Current Sense from FET PC Boards (J6-7)
Secondary Current Sense Return from FET PC Boards (J6-8)
Over Temperature Sense from FET PC Boards (J6-9)
Over Temperature Sense from FET PC Boards (J6-10)
J8-1
J8-2
J8-3
J8-4
J8-5
J8-6
J8-7
J8-8
J8-9
J8-10
+12 vdc to FET PC Boards (J6-1)
Return for +12 vdc to FET PC Boards (J6-2)
PWM Output (B) to FET PC Boards (J6-3)
PWM Return to FET PC Boards (J6-4)
Primary Current Sense from FET PC Boards (J6-5)
Primary Current Sense Return from FET PC Boards (J6-6)
Secondary Current Sense from FET PC Boards (J6-7)
Secondary Current Sense Return from FET PC Boards (J6-8)
Over Temperature Sense from FET PC Boards (J6-9)
Over Temperature Sense from FET PC Boards (J6-10)
APPENDIX
A-6
A-02323
Manual 0-2697
J9-1
J9-2
J9-3
J9-4
J9-5
J9-6
J9-7
J9-8
J9-9
J9-10
J9-11
J9-12
J9-13
J9-14
J9-15
J9-16
J9-17
J9-18
J9-19
J9-20
36 VAC (b) from Logic PC Board (J4-1)
36 VAC (a) from Logic PC Board (J4-2)
36 VAC (a) from Logic PC Board (J4-3)
36 VAC (b) from Logic PC Board (J4-4)
36 VAC CT Return from Logic PC Board (J4-5)
Return for Transfer Mod Enable
36 VAC CT Return from Logic PC Board (J4-7)
Active Low Transfer Mod Enable Signal
Active Low Over Temperature Sense from FET PC Boards to Logic PC Board (J4-9)
Over Temperature Sense from FET PC Boards to Logic PC Board (J4-10)
Return for Master Enable Signal to Logic PC Board (J4-11)
Active Low Master Enable Signal from Logic PC Board (J4-12)
Return for Pilot Enable Signal to Logic PC Board (J4-13)
Active Low Pilot Enable Signal from Logic PC Board (J4-14)
Return for PSR Signal from Logic PC Board (J4-15)
Active Low PSR Signal to Logic PC Board (J4-16)
Return for Demand Signal to Logic PC Board (J4-17)
Demand Signal from Logic PC Board (J4-18)
Return for Demand Signal from Logic PC Board (J4-19)
Not Used
TP1
TP2
TP3
TP4
TP5
TP6
TP7
TP8
TP9
TP10
TP11
TP12
TP13
TP14
TP15
TP16
Logic Ground
+12 vdc
Active Low Transfer Mod Enable Signal
+5 vdc
PWM Signal (B)
PWM Signal (A)
Secondary Current Sense
Primary Current Sense
Active Low Reset Signal
+6 vdc
Current Demand Signal
Active Low Shutdown Signal
Return for Secondary Current Sense
-12 vdc
Active Low Pilot Enable Signal
Active Low Master Enable Signal
D4
D20
Power Enable Indicator
Reset Indicator
Manual 0-2697
A-7
APPENDIX
APPENDIX 6: PILOT/OUTPUT PC BOARD LAYOUT AND
WIRING CONNECTION DIAGRAM
Pilot/Output PC Board
D5
TP4
TP5
TP8
TP2
TP6
TP3
TP1
A-02311
J13
J12
TP7
Pilot Output PC Board Signals
J12-1
J12-2
J12-3
J12-4
J12-5
J12-6
J12-7
J12-8
J12-9
J12-10
J12-11
J12-12
J12-13
J12-14
J12-15
J12-16
Torch Switch from J22-3 Torch Control
Shield to J22-1
Torch Switch from J22-4 Torch Control
Shield to J22-2
Not Used
Not Used
OK-To-Move To J22-12 (Isolated Contacts from Logic PC Board)
OK-To-Move To J22-14 (Isolated Contacts from Logic PC Board)
Enable Jumper
Not Used
Enable Jumper
Not Used
Not Used
Return to J22-8
Not Used
Not Used
APPENDIX
A-8
Manual 0-2697
J13-1
J13-2
J13-3
J13-4
J13-5
J13-6
J13-7
J13-8
J13-9
J13-10
J13-11
J13-12
J13-13
J13-14
J13-15
J13-16
J13-17
J13-18
J13-19
J13-20
J13-21
J13-22
J13-23
J13-24
Active Low Start signal (Torch Switch)
Torch Switch Return
OK-To-Move (Isolated Contacts from Logic PC Board)
OK-To-Move (Isolated Contacts from Logic PC Board)
Ground
Not Used
Drag Voltage Sensing (Tip Voltage)
Not Used
PS(-) Voltage Sensing
Not Used
Enable Jumper
Enable Jumper
Not Used
36 VAC (a) from Logic PC Board
36 VAC (b) from Logic PC Board
36 VAC CT Common
Return for Pilot Signal
Active Low Pilot Signal
Not Used
Active Low Overtemp Signal
Return for Overtemp Signal
Active Low CSR Sense Signal J98-1
Return for CSR Sense Signal J98-2
+12 vdc to Current Sense Board J98-3
TP1
TP2
TP3
TP4
TP5
TP6
TP7
TP8
Ground
+15 vdc
Pilot Switch to Gate Drive PC Board
Pilot Drive Signal
Not Used
Active Low Pilot Drive Signal
Not Used
Pilot Switch to Gate Drive PC Board
D5
Pilot ON Indicator
Stiff CD Coil Wire
Wire #13 To Resistors
Output Inductor Lead
Output Inductor Lead
Wire #17 (Black)
Wrapped Around Wire #15
Wire From Transformer
Wire #14 To Resistors
Jumper Wire
Ground (Green) Wire
Jumper Wire
Wire #15 (Red)
From Bulkhead
Wire From Transformer
Wire #17 (Black)
Wrapped Around Wire #15
Twisted 3-Wire Harness
From Current Sensor PCB
Work Cable
A-02558
J12
J13
4-Wires #12 (Red)
From FET/Heatsink
Assemblies
Manual 0-2697
A-9
APPENDIX
APPENDIX 7: CD PC BOARD LAYOUT
TP2
TP1
J11-1
J11-3
J11-4
J11-5
J11
TP3
A-01208
E2
E1
CD PC Board Signals
J11-1
J11-2
J11-3
J11-4
J11-5
J11-6
J11-7
J11-8
36 VAC (b) from Logic PC Board (J5-1)
36 VAC CT Return (J5-2)
36 VAC (a) from Logic PC Board (J5-3)
Active Low CD Enable Signal from Logic PC Board (J5-4)
Return for CD Enable Signal from Logic PC Board (J5-5)
Not Used
Not Used
Not Used
TP1
TP2
TP3
Logic Ground or Return
+12 vdc
Not Used
E1
E2
CD output
CD Output
APPENDIX
A-10
Manual 0-2697
APPENDIX 8: INPUT PC BOARD LAYOUT
Component Side of PC Board
E5
E6
(-)
(-)
(+)
Solder Side of PC Board
LT1
E1
E1
E2
E2
E4
E7
E7
E8
E8
E3
CGND
A-02313
Input PC Board
C
A
B
C
(-)
(-)
(+)
LT1
AC Input (L1)
AC Input (L2)
AC Input (L3)
Rectifier (-) Output
Rectifier (-) Output
Rectifier (+) Output
Power ON Indicator
E1
E2
E3
E4
E5
E6
E7
E8
Rectifier (+) Output to INR
Rectifier (+) Output to INR
Rectifier (-) Output to Capacitor PC Boards (A & C) and Input Voltage Selection
Rectifier (-) Output to Capacitor PC Boards (A & C) and Input Voltage Selection
AC Input (L1) for LT1
AC Input (L2) for LT1
Rectifier (+) from INR
Rectifier (+) to Capacitor PC Boards (B & D) and Input Voltage Selection
B
A
CGND Chassis Ground
Manual 0-2697
A-11
APPENDIX
APPENDIX 9: FET PC BOARD LAYOUT
E1
E14
E15
E17
E19
Component Side Of PC Board
E16
E19
E17
E15
E18
E14
E19
XFMR SEC
E17
T3
- OUTPUT
E15
MAIN XFMR PRI
E14
MAIN XFMR PRI
MAIN XFMR SEC
E16
E18
+ OUTPUT
J6
FET PCB ASSY
10
1
Solder Side Of PC Board
E18
APPENDIX
E16
A-00479
J6
A-12
Manual 0-2697
FET PC Board Signals (Upper and Lower Assemblies)
J6-1
J6-2
J6-3
J6-4
J6-5
J6-6
J6-7
J6-8
J6-9
J6-10
+12 vdc from the Gate Drive Board upper J7-1 Lower J8-1
+12 vdc RTN from the Gate Drive Board upper J7-2 Lower J8-2
PWM Output from the Gate Drive Board upper J7-3 Lower J8-3
PWM Output RTN J6-2 from the Gate Drive Board upper J7-4 Lower J8-4
PRI CURRENT SENSE to the Gate Drive Board upper J7-5 Lower J8-5
PRI CURRENT SENSE RTN to the Gate Drive Board upper J7-6 Lower J8-6
SEC CURRENT SENSE to the Gate Drive Board upper J7-7 Lower J8-7
SEC CURRENT SENSE RTN to the Gate Drive Board upper J7-8 Lower J8-8
OVER TEMP RTN to the Gate Drive Board upper J7-9 Lower J8-9
Active Low OVER TEMP Signal to the Gate Drive Board upper J7-10 Lower J8-10
E1
E14
E15
E16
E17
E18
E19
HEATSINK GND To HEAT SINK
MAIN XFMR PRI to MAIN XFMR PRI E14
MAIN XFMR PRI to MAIN XFMR PRI E15
MAIN XFMR SEC from MAIN XFMR SEC E16
OUTPUT (-) to OUTPUT INDUCTOR L1
OUTPUT (+) to Current Sense Transformer and E8 on Output Board
MAIN XFMR SEC from MAIN XFMR SEC E19
Manual 0-2697
A-13
APPENDIX
APPENDIX 10: CAPACITOR PC BOARD LAYOUT
E13A
E12A
E13B
E12B
E26
E25
A-01418
E13
E12
E13C
E12C
Capacitor PC Board Signals
E12
E12A
E12B
E12C
E13
E13A
E13B
E13C
E25
E26
Positve Rail to FET Board
Positve Rail to FET Board
Positve Rail to FET Board
Positve Rail to FET Board
Negative Rail to FET Board
Negative Rail to FET Board
Negative Rail to FET Board
Negative Rail to FET Board
Positive Input from E8 on Input PC Board
Negative Input from E3 & E4 Input PC Board
APPENDIX
A-14
Manual 0-2697
APPENDIX 11: CURRENT SENSOR PC BOARD LAYOUT
J15
A-01419
Current Sensor PC Board Signals
J15-1
J15-2
J15-3
Active Low CSR Sense Signal
Ground
+12 vdc
Manual 0-2697
A-15
APPENDIX
APPENDIX 12: 36VAC CIRCUIT DIAGRAM
Pilot/Output
PC Board
CD PC Board
2 3 1
J11
J5 2
3
14 15 16
J13
1 17 18 19
Logic PC
Board
J4
J9
5
7
3
2
1
4
5
7
3
2
1
4
J1
3
5
Auxiliary
36 VAC
1
Transformer
Outputs
2
115 VAC
6
Gate Drive
PC Board
Input Voltage
Sense
A-02325
J3 3
1
2
4
ON/OFF
Switch
J9
1
2
3
J4-5
J4-7
4
5
Gate Drive
PC Board
7
APPENDIX
A-16
Manual 0-2697
APPENDIX 13: RECOMMENDED ROUTINE MAINTENANCE
SCHEDULE FOR LIQUID COOLED PLASMA CUTTING
SYSTEMS
This schedule applies to all types of liquid cooled plasma cutting systems. Some systems will not have all the parts
listed and those checks need not be performed.
NOTE
The actual frequency of maintenance may need to be adjusted according to the operating environment.
Daily Operational Checks or Every Six Arc Hours:
1. Check torch parts, replace if damaged.
2. Check plasma and secondary supply and pressure/flow.
3. Purge plasma gas line to remove any moisture build-up.
4. Check deionizer bag/cartridge, replace if color is predominantly yellow.
5. Check coolant pressure (100 - 120 psi).
Weekly or Every 30 Arc Hours:
1. Check fan for proper operation and adequate air flow.
2. Blow or vacuum dust and dirt out of the entire machine.
CAUTION
Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to
interfere with sensitive electrical components and cause damage to the unit.
Six Months or Every 720 Arc Hours:
1. Remove and clean in-line filter screens.
2. Check cables and hoses for leaks or cracks, replace if necessary.
3. Check all contactor points for severe arcing or pits, replace if necessary.
4. Check all pillow blocks and bearings, clean and lubricate if necessary.
5. Check fan, pump and pulley belts for wear or cracking, replace if necessary.
Twelve Months or Every 1500 Arc Hours:
1. Drain coolant, fill with distilled water, turn on main power switch and let machine run for approximately 30
minutes.
WARNING
DO NOT energize the Torch.
Drain distilled water and replace with Thermal Arc Coolant. Use Extra-CoolTM Coolant (Catalog # 7-3580) or Ultra-CoolTM
Coolant (Catalog # 7-3581) for environments below +10° F (-12° C).
2. Check radiator fins, clean and comb out if necessary.
3. Repeat six month maintenance.
Manual 0-2697
A-17
APPENDIX
APPENDIX 14: SYSTEM SCHEMATIC (Unit Rev AU or Earlier)
A-02400
APPENDIX
A-18
Manual 0-2697
NOTE
Transformer T3 in earlier product does not have fuses as part of the Transformer Assembly.
A-02400
Manual 0-2697
A-19
APPENDIX
APPENDIX 15: SYSTEM SCHEMATIC (Unit Rev AV - AY)
Art # A-03051
APPENDIX
A-20
Manual 0-2697
NOTE
Transformer T3 in earlier product does not have fuses as part of the Transformer Assembly.
Art # A-03051
Manual 0-2697
A-21
APPENDIX
APPENDIX 16: SYSTEM SCHEMATIC (Unit Rev AZ or Later)
Art # A-04328
APPENDIX
A-22
Manual 0-2697
Art # A-04328
Manual 0-2697
A-23
APPENDIX
This Page Left Blank
APPENDIX
A-24
Manual 0-2697
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Thermadyne USA
Thermadyne Asia Sdn Bhd
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: sales@thermalarc.com
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Thermadyne Canada
Cigweld, Australia
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Europe
Thermadyne Italy
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
Thermadyne International
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
Corporate Headquarters
16052 Swingley Ridge Road
Suite 300
St. Louis, MO 63017
Telephone: 636-728-3000
Email: TDCSales@Thermadyne.com
www.thermadyne.com
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