Thermadyne Thermal Dynamics PAK MASTER 50XL User manual

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

WARNING
WARNING
Read and understand this entire Service Manual and your
employer’s safety practices before installing, operating, or
servicing the equipment.
While the information contained in this Service Manual repre-
sents our best judgement, Thermal Dynamics Corporation
assumes no liability for its use.
Pak Master®50XL Air Plasma Cutting Power Supply
Service Manual Number 0-2587
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
[phone]
Copyright 1997 by
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written
permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liabil-
ity to any party for any loss or damage caused by any error or
omission in the Pak Master®50XL Air Plasma Cutting Power
Supply Service Manual, whether such error results from negli-
gence, accident, or any other cause.
Printed in the United States of America
August 11, 1999

TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION .................................................................................................. 1
1.01 Notes, Cautions andWarnings ...................................................................... 1
1.02 Important Safety Precautions ........................................................................ 1
1.03 Publications ................................................................................................... 2
1.04 Note, Attention et Avertissement ................................................................... 3
1.05 Precautions De Securite Importantes ............................................................ 3
1.06 Documents De Reference ............................................................................. 5
1.07 Declaration of Conformity .............................................................................. 6
1.08 Statement ofWarranty ................................................................................... 7
SECTION 2:
INTRODUCTION ................................................................................................................. 9
2.01 Scope Of Manual........................................................................................... 9
2.02 General Service Philosophy .......................................................................... 9
2.03 Service Responsibilities................................................................................. 9
SECTION 3:
DESCRIPTION .................................................................................................................. 11
3.01 Scope .......................................................................................................... 11
3.02 General Description..................................................................................... 11
3.03 Specifications/Design Features ................................................................... 11
3.04 Power Supply Options and Accessories ...................................................... 12
SECTION 4:
SERVICETROUBLESHOOTING DIAGNOSTICS ............................................................. 13
4.01 Introduction.................................................................................................. 13
4.02 Periodic Inspection & Procedures................................................................ 13
4.03 Common Operating Problems ..................................................................... 13
4.04 Troubleshooting Guide - General Information............................................... 14
4.05 Circuit Fault Isolation ................................................................................... 15
4.06 Main Input and Internal Power Problems ..................................................... 16
4.07 Pilot Arc Problems ....................................................................................... 19
4.08 Main Arc Problems ...................................................................................... 20
4.09 Test Procedures........................................................................................... 20
SECTION 5:
REPAIRS & REPLACEMENT PROCEDURES................................................................... 29
5.01 Introduction.................................................................................................. 29
5.02 Anti-Static Handling Procedures .................................................................. 29
5.03 Parts Replacement - General Information.................................................... 29
5.04 Major External Parts Replacement .............................................................. 30
5.05 Access Panel Parts Replacement................................................................ 31
5.06 Front Panel Parts Replacement ................................................................... 31
5.07 Left Side Internal Component Parts Replacement ....................................... 32
5.08 Rear Panel Parts Replacement ................................................................... 34
5.09 Right Side Internal Component Parts Replacement..................................... 35

TABLE OF CONTENTS (continued)
SECTION 6:
PARTS LISTS.....................................................................................................................37
6.01 Introduction.................................................................................................. 37
6.02 Ordering Information.................................................................................... 37
6.03 Major External Replacement Parts List........................................................ 38
6.04 Access Panel Replacement Parts List ......................................................... 40
6.05 Front Panel Replacement Parts List............................................................. 42
6.06 Left Side Internal Component Replacement Parts List ................................ 44
6.07 Rear Panel Replacement Parts List ............................................................. 46
6.08 Right Side Internal Component Replacement Parts List .............................. 48
6.09 Options and Accessories............................................................................. 50
APPENDIX I: INPUT WIRING REQUIREMENTS ...................................................................... 51
APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ........................................... 52
APPENDIX III: POT/LED PC BOARD LAYOUT.......................................................................... 53
APPENDIX IV: LOGIC PC BOARD LAYOUT ............................................................................. 54
APPENDIXV: GATE DRIVE PC BOARD LAYOUT .................................................................... 56
APPENDIXVI: PILOT OUTPUT PC BOARD LAYOUT............................................................... 58
APPENDIX VII: CD PC BOARD LAYOUT .................................................................................. 60
APPENDIXVIII: INPUT PC BOARD LAYOUT............................................................................ 61
APPENDIX IX: FET PC BOARD LAYOUT ................................................................................. 62
APPENDIX X: CAPACITOR PC BOARD LAYOUT ..................................................................... 64
APPENDIX XI: 36VAC CIRCUIT DIAGRAM............................................................................... 65
APPENDIX XII: SYSTEM SCHEMATIC ..................................................................................... 66