appendix 1 - Victor Technologies

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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. Indicator Meaning D4 D20 Gate Drive PC Boards 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. 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. Pilot PC Board Indicator Meaning D5 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 NOTE 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. 4.04 Common Operating Problems WARNINGS Disconnect primary power at the source before disassembling the power supply, torch, or torch leads. 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. CAUTION Sparks from the cutting process can cause damage to coated, painted, and other surfaces such as glass, plastic and metal. 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 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 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. 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. 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. F. Common Cutting Faults 1. Insufficient Penetration a. Cutting speed too fast b. Torch tilted too much c. Metal too thick 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. Torch standoff too high from workpiece c. Worn torch parts d. Improper cutting current e. Improper gas selection for cutting material 4. Short Torch Parts Life a. Oil or moisture in air source b. Exceeding system capability (material too thick) 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. A. Basic Troubleshooting 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. 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. NOTE Follow all instructions as listed and complete each in the order presented. Manual 0-2697 4-5 SERVICE
Page 1: PLASMA CUTTING POWER SUPPLY PAK Mas
Page 4 and 5: TABLE OF CONTENTS SECTION 1: GENERA
Page 7 and 8: SECTION 1: GENERAL INFORMATION 1.01
Page 9 and 10: 6. ANSI Standard Z49.2, FIRE PREVEN
Page 11 and 12: ultra-violets très forts. Ces rayo
Page 13 and 14: 1.07 Declaration of Conformity Manu
Page 15 and 16: SECTION 2: INTRODUCTION 2.01 Scope
Page 17 and 18: SECTION 3: DESCRIPTION 3.01 Scope o
Page 19 and 20: 15. Weight Power Supply with Torch:
Page 21 and 22: 4.01 Introduction SECTION 4: SERVIC
Page 23: The Logic PC Board controls the tim
Page 27 and 28: Set the Power Supply RUN/SET switch
Page 29 and 30: 4. Clogged coolant filter and/or in
Page 31 and 32: a. Check continuity per appropriate
Page 33 and 34: NOTE Art may differ from actual uni
Page 35 and 36: H. Temperature Circuit Test The Pow
Page 37 and 38: ange, check between the two output
Page 39 and 40: SECTION 5: REPLACEMENT PROCEDURES 5
Page 41 and 42: C. Work Cable Replacement 1. Remove
Page 43 and 44: 5.06 Left Side Center Chassis Parts
Page 45 and 46: I. FET/Heatsink Assembly Replacemen
Page 47 and 48: G. Coolant Reservoir Replacement CA
Page 49 and 50: 9. Carefully slide the rear panel o
Page 51 and 52: M. Current Sense PC Board Assembly
Page 53 and 54: E. Motor (M5) / Fan / Pump Replacem
Page 55 and 56: 7. Remove rear panel from unit by c
Page 57 and 58: 6.01 Introduction SECTION 6: PARTS
Page 59 and 60: 6.04 Access Panel Replacement Parts
Page 61 and 62: 3 2 4 6 10 9 9 1 Manual 0-2697 6-5
Page 63 and 64: 12 1 5 4 3 17 10 11 21 10 Manual 0-
Page 65 and 66: 9 A-02278 3 11 10 20 6 5 23x4274 Ma
Page 67 and 68: 11 10 4 15 5 9 11 6 10 4 15 5 9 A-0
Page 69 and 70: APPENDIX 1: INPUT WIRING REQUIREMEN
Page 71 and 72: Pot/LED PC Board Signals APPENDIX 3
Page 73 and 74: J3-10 +12 vdc J3-11 Active Low Sign
Page 75 and 76:
J9-1 36 VAC (b) from Logic PC Board
Page 77 and 78:
J13-1 Active Low Start signal (Torc
Page 79 and 80:
E1 E2 E7 E8 Component Side of PC Bo
Page 81 and 82:
FET PC Board Signals (Upper and Low
Page 83 and 84:
APPENDIX 11: CURRENT SENSOR PC BOAR
Page 85 and 86:
APPENDIX 13: RECOMMENDED ROUTINE MA
Page 87 and 88:
NOTE Transformer T3 in earlier prod
Page 89 and 90:
NOTE Transformer T3 in earlier prod
Page 91:
Art # A-04328
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