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Thermal Dynamics PakMaster XLPLUS 50 User Manual

Thermal Dynamics PakMaster XLPLUS 50
74 pages
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Manual No. 0-2745
August 12, 1999
Service Manual
A-02464
Air Plasma Cutting
Power Supply

Table of Contents

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Thermal Dynamics PakMaster XLPLUS 50 Specifications

General IconGeneral
BrandThermal Dynamics
ModelPakMaster XLPLUS 50
CategoryPower Supply
LanguageEnglish

Summary

SECTION 1: GENERAL INFORMATION

1.02 Important Safety Precautions

Lists critical safety guidelines for operating and maintaining plasma arc equipment.

1.05 Precautions De Securite Importantes

Lists important safety precautions relevant to plasma arc equipment operation.

SECTION 4: SERVICE TROUBLESHOOTING DIAGNOSTICS

4.01 Introduction

Introduces service diagnostics for the Pak Master 50XL PLUS Power Supply.

4.03 Common Operating Problems

Lists common operational issues and potential causes for the plasma cutting system.

4.04 Troubleshooting Guide - General Information

A. Troubleshooting and Repair

Provides guidance for diagnosing and repairing the power supply unit.

B. Advanced Troubleshooting

Details advanced troubleshooting requiring power supply disassembly and live measurements.

4.05 Circuit Fault Isolation

A. Initial Setup Conditions

Details the initial setup conditions required for testing and troubleshooting the unit.

B. Main Input and Internal Power Tests

Describes tests for the main power input and internal power circuits.

C. Pilot Arc Test

Outlines the procedure for testing the pilot arc functionality of the plasma system.

4.06 Main Input and Internal Power Problems

A. Main power line fuses blow as soon as main disconnect is closed

Lists causes for main power fuses blowing immediately upon closing the disconnect.

B. Main power line fuses blow 3-6 seconds after the ON/OFF Switch is turned on

Lists causes for main power fuses blowing after the ON/OFF switch is activated.

C. AC indicator on front panel of power supply is OFF; Fan does not operate

Lists causes for the AC indicator being OFF and the fan not operating.

4.06 Main Input and Internal Power Problems (continued)

4.07 Pilot Arc Problems

A. AC indicator ON; TEMP indicator off; No gas flow; GAS and DC indicators OFF

Troubleshoots pilot arc issues with specific indicator and flow conditions.

B. AC indicator ON; TEMP indicator off; Gas flows; GAS indicator ON; DC indicator blinks; Small arc may be visible in torch

Addresses pilot arc problems with specific indicator states and a visible small arc.

4.07 Pilot Arc Problems (continued)

4.08 Main Arc Problems

A. Main cutting arc will not initiate

Addresses the problem where the main cutting arc fails to initiate.

B. When operating at amperages over 35 amps, the amperage drops off after the main cutting arc initiates.

Troubleshoots amperage drop-off at high amperages after main arc initiation.

4.09 Test Procedures

A. Safety Precautions

Lists essential safety precautions before performing tests on the power supply.

4.09 Test Procedures (continued)

4.09 Test Procedures (continued)

D. Input PC Board/Input Diode Test

Details testing the Input PC Board and its input diodes for shorts.

E. Main Contactor (MC1) Test

Outlines the procedure for testing the main contactor (MC1) for proper operation.

5.02 Anti-Static Handling Procedures (continued)

5.07 Left Side Internal Component Parts Replacement

5.07 Left Side Internal Component Parts Replacement (continued)

APPENDIX VIII: FET PC BOARD LAYOUT

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