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Thread: Thermal Dynamics PakMaster 100XL problem - output inductor

  1. #1
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    Thermal Dynamics PakMaster 100XL problem - output inductor

    So my TD Pakmaster 100XL i've owned for about 15 years took a dump today. It wouldn't start the HF arc like normal, tried several times
    to get it going and finally gave up and took side covers off, where i immediately found the issue.

    The output inductor was sparking through a cracked insulator to a bolt head. The bolt head was eroded away and the insulator fell apart when i touched it.
    The part that fell apart was sort of powdered metal, makes me think of ferrite from a magnet, but it wasn't magnetic that i could tell. if it was ferrite,
    it's a wierd U-shaped piece and i won't be able to make one nor probably find one on something this old. Does anyone think i could just machine one from plastic/delrin?

    Also, the corner of the conductor (very heavy wire) has some burns. It doesn't look like it's down into any of the other windings, so i am assuming i can polish/sand and coat with
    some varnish.

    Does anyone have any thoughts on this?

    See pics.
    Miller Syncrowave 300(s)
    Miller 330 A/BP
    Miller CP-200 Haas / Kamp'd / CP-300 in process
    Miller Radiator 1
    Miller 30A /S-52E feeders
    Hobart GR-303

  2. #2
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    Re: Thermal Dynamics PakMaster 100XL problem - output inductor

    Quote Originally Posted by 86turbodsl View Post
    So my TD Pakmaster 100XL i've owned for about 15 years took a dump today. It wouldn't start the HF arc like normal, tried several times
    to get it going and finally gave up and took side covers off, where i immediately found the issue.

    The output inductor was sparking through a cracked insulator to a bolt head. The bolt head was eroded away and the insulator fell apart when i touched it.
    The part that fell apart was sort of powdered metal, makes me think of ferrite from a magnet, but it wasn't magnetic that i could tell. if it was ferrite,
    it's a wierd U-shaped piece and i won't be able to make one nor probably find one on something this old. Does anyone think i could just machine one from plastic/delrin?

    Also, the corner of the conductor (very heavy wire) has some burns. It doesn't look like it's down into any of the other windings, so i am assuming i can polish/sand and coat with
    some varnish.

    Does anyone have any thoughts on this?

    See pics.
    I know a lot of repair guys who save everything. I'll start asking around on Monday. Great pics.
    Thermal Arc 320SP ( Lorch )
    Cobra Pythons
    Thermal Arc 300 AC/DC ( Sanrex )
    ESAB 301i AC/DC ( Lorch )
    Thermal Arc 161STL ( WTL )
    Thermal Arc 190S ( Sanrex )
    Cut Master 82, 42. Cut45 ( WTL )
    Victor Gas Apps.
    Boxes and boxes of welding crap.

  3. #3
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    Re: Thermal Dynamics PakMaster 100XL problem - output inductor

    I checked the coil and no shorts. I will shoot it with some varnish and see about some plastic for isolator.

    Sent from my LG-TP450 using Tapatalk
    Miller Syncrowave 300(s)
    Miller 330 A/BP
    Miller CP-200 Haas / Kamp'd / CP-300 in process
    Miller Radiator 1
    Miller 30A /S-52E feeders
    Hobart GR-303

  4. #4
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    Re: Thermal Dynamics PakMaster 100XL problem - output inductor

    I have varnish and plastic to make a part showing up today. I confirmed that the part that fell apart is some sort of ferrite. Non magnetic itself, but sticks to a magnet. Without having that, i'm betting the arc is a little less stable, but probably not enough flux loss to worry about i think. We shall see tonight.
    Miller Syncrowave 300(s)
    Miller 330 A/BP
    Miller CP-200 Haas / Kamp'd / CP-300 in process
    Miller Radiator 1
    Miller 30A /S-52E feeders
    Hobart GR-303

  5. Likes Rondo liked this post
  6. #5
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    Re: Thermal Dynamics PakMaster 100XL problem - output inductor

    I shot the coil with 2 coats of electrical varnish today and made a new insulator out of nylon and can confirm the plasma is back to 100pct functional. Seems to be no different in operation.

    Sent from my LG-TP450 using Tapatalk
    Miller Syncrowave 300(s)
    Miller 330 A/BP
    Miller CP-200 Haas / Kamp'd / CP-300 in process
    Miller Radiator 1
    Miller 30A /S-52E feeders
    Hobart GR-303

  7. Likes Munkul, Rondo liked this post

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