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Thermal Dynamics CutMaster 81 Service

1. TP5 Board Signals 12vdcfrom Main Power PCB 12vdcfrom Main PCB DC Com DC Com MC1 ON signal Tip Sense RUN SET Signal Logic Low for SET Logic Low PS1 Pressure Switch closed Pressure OK Logic Low TS1 Closed OVERTEMP Logic Low CSR Logic Low
2. 1 2 3 4 5 3 L1 w1 a E12A GATE E5 FA DRIVE E13 600VAC L2 wi 3 PHASE 2 E18 A INPUT wi zs E19A INPUT DIODE ASSY 19X2073 E21A IGBT BOARD SSY 19X1815 ale E12B GATE FILTERING E17B DRIVE J3B B M1 E19B FAN1 3 10A 600V E21B IGBT BOARD ava ul ASSY 19X1815 M2 FAN2 1 P31 28VAC B 21 28VAC 22 4 2 5 _ ON OFF SW 912 E 8 28VAC B TO BIAS SUPPLY P30 SW1 26 lg 2 RUN 1 P25 MODE SW 4 der 1 RAR OFF lt PILOT PCB F9 SW2 E5 152 E6 751 CURRENT ADJUST 20 80 FOR CM101 J27 70 20 60 FOR CM81 POT HIGH POT WIPER 27 CE MAIN TRA
3. 5 pesi ysss5999999999999999999999999998 J26 E27 E30 MAIN PCB ASSEMBLY 19 1929 460V 19X1912 208 230V 19 1930 400V 19X1931 6000 Art 4 03651 IGBT A E33 E4 J30 J31 E23 IGBT B Main Printed Circuit Board Layout Logic PCB Not Shown TROUBLESHOOTING 4 10 Manual 0 2957 4 08 Pilot Arc Problems A WARNING The following tests must be performed with the power supply connected to primary input power There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair without proper training in power elec tronics measurement and troubleshooting tech niques Locate your symptom below A Torch will not pilot gas flows AC indicator s ON GAS TEMP 2 and DC indicat
4. 6 7 8 9 10 DESCRIPTION LOCATION FUSE 6 10A 600V KTK FUSE 0 9A RESETABLE OUTPUT INDUCTOR FAN 4 5 220VAC FAN 4 5 220VAC PRESSURE SWITCH GAS SOLENOID A SWITCH SWITCH RUN SET RAR MAIN TRANSFORMER TEMP SENSOR IGBT HEATSINK TEMP SENSOR INDUCTOR MAIN CONTACTOR NOTES UNLESS OTHERWISE SPECIFIED 1 DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS IS FOR REFERENCE ONLY OPTIONAL AUTOMATION INTERFACE CONNECTIONS B PLUGS INTO J27 ON MAIN BOARD ALTERNATE 20 PIN HEADER TEM 20 POSITION TERMINAL STRIP d I I J14 P14 P3 1 1 1 212 9 A M TORCH SWITCH ac 414 7 4 515 6 6 6 49X2041 H OK TO MOVE amp Gas 1818 OPTIONAL 3 go 1 _ pvpEp OUTPUT UE s ADAPTER HARNESS USED P1 J1 T REMOTE CURRENT CONTROL WHEN REMOTE CURRENT CSR 1 CSR 8 CONTROL IS USED WITH 221 2 2 DC common 4 4 DC COMMON AUTOMATION 1 1 12VDC 3 c REPLACES CONNECTIONS TS2 1212 FROM J27 TO J14 151 TORCH Sw L114 NEG 8 CPC HOUSING 4 SWITCH Es 14 move 0 E 09 sent ED 5 Et 1 8 zi LOGIC COMMON L t 3 ARC VOLTS OUTPUT INDUCTOR L
5. TP4 FUSE 1 U1 423 J24 434 432 J29 J33 2 oy ee 5 D ENT e al TE da Em i J27 2 19 1929 19X1912 19X1930 19X1931 MAIN PCB ASSEMBLY 460V 400V 600V 208 230 Art A 03651 IGBT A Main Power PC Board Signals 1 1 L1 Input 1 4 L3 Input J15 1 Fan M1 J15 2 Fan M1 J15 3 Not used J15 4 Not used J15 5 Fan M2 J15 6 Fan M2 J16 1 Not used J16 2 Not used J17 1 Not used 117 2 Not used APPENDIX E33 E4 J30 A 4 J18 1 J18 2 J18 3 J18 4 J18 5 J18 6 J18 7 J18 8 J23 1 J23 2 J23 3 J24 1 J24 2 J24 3 J24 4 J24 5 J24 6 J24 7 J24 8 Not used Not used 28 VAC B 28 VAC A On Off Switch On Off Switch Run Set Switch Run Set Switch Not used Not used Not used Gas Solenoid SOL 1 Gas Solenoid SOL 1 Pressure Switch PS1 Press
6. 000000000000000000000 TP9 TP10 it 893 m G 11 fom H4 Art A 03654 TROUBLESHOOTING Contactor Voltage Readings Nominal Contactor Voltage Input Voltage Points Range 2 Check for 28 at J23 1 to J23 3 on the Main PC Board a If greater than 30 VAC input line power is too high b If there is no AC power check the fuse If the fuse is okay the auxiliary transformer is faulty Replace the Main PC Board E Gas Solenoid Circuit Test Connections to Main PCB Main Contactor Art A 03194 400 415 460 600 Volt Main Input Contactor Three Phase Input Power Shown in Contactor Art A 03212 208 230 Volt Main Input Contactor TROUBLESHOOTING 4 18 Make the following voltage checks and replace the faulty part as required 1 Place the R
7. m m lt lt LLI 5 o o sa ES d a 9 e La RUM P FUR 0 2 0 55 Co di 0 00 20 Q Go QOO lt os E 9 0 0 a A18W3S6V dod 1891 5 E 99 m JO WA 9 Cw D 0 9 o no ii nm R RR 10 E12B E17B E17A A 03704 Manual 0 2957 A 10 APPENDIX APPENDIX 9 OUTPUT DIODE PC BOARD LAYOUT Output Diode A Output Diode B CO tens Te 2 O7 15 OUTPUT DIODE BD 19X1757 1 REV AA xu A 03152 Manual 0 2957 APPENDIX APPENDIX 10 OUTPUT BOARD WIRING DIAGRAM To Torch To Pilot PCB Main PCB To Pilot PCB TP1 Output Chassis Ground J39 J40 E36 Diode B E53 1 J39 8 1 140 000000 x ou oy fer E ts gt E 2 ie Llp see Output QUTPUT POWER A
8. 417 415 im ai sa E5 ES Es J27 J26 E27 E30 MAIN PCB ASSEMBLY 191929 191912 191930 191931 4607 208 230V 4007 6007 IGBT A Art A 03651 E23 IGBT B Main Printed Circuit Board Layout logic board not shown TROUBLESHOOTING 46 Manual 0 2957 11 Faulty ON OFF switch 4 Faulty Temperature Sensor Switch Measure for 28 VAC on the Main PC Board be a Shut input power off Check IGBT Heatsink tween 18 5 to J18 6 Temp Sensor 151 Disconnect wire connector P29 from terminal J29 on PC Board Check a If voltage is not present replace the ON OFF connector pins 1 and 2 for 10K ohm 25 at Se ambient t
9. MAIN ASSEMBLY 191929 19X1912 191930 191931 4607 208 230V 400V 6007 Art A 03651 IGBT A IGBT B E23 Main Printed Circuit Board Layout logic board not shown TROUBLESHOOTING 4 14 Manual 0 2957 4 10 Test Procedures The test procedures in this subsection are referenced in the troubleshooting section A 1 Safety Precautions Significant DC Voltage exists after removal of input power Allow two minutes for discharge time Volt age measured on input capacitors must be zero be fore performing service on the power supply Do Not touch electrical components with any part of the human body when power is applied Keep away from any moving parts Hot surfaces can cause severe burns Allow equip ment to cool before servicing 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 Misaligned plugs can cause printed circuit board dam age Be sure plugs are properly aligned and com pletely seated Excessive pressure can damage printed circuit boards Use only minimal pressure and gentle movement when disconnecting or connecting printed circuit board plugs Diode Testing Basics A Disconnect pr
10. 6 7 8 9 10 TABLE 1 COMP DESCRIPTION LOCATION SEE CHART 1 0 9A RESETABLE OUTPUT INDUCTOR FAN 4 5 220VAC FAN 4 5 220 PRESSURE SWITCH GAS SOLENOID A SWITCH RUN SET RAR 500 4 10 500v t 4A 500v TEMP SENSOR IGBT HEATSINK TEMP SENSOR INDUCTOR MAIN CONTACTOR NOTES UNLESS OTHERWISE SPECIFIED 1 DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS IS FOR REFERENCE ONLY OPTIONAL AUTOMATION INTERFACE CONNECTIONS B Hi o fi RES En Rid ces Rn abd Ed EE RES ze cs nu I PLUGS INTO J27 I ON MAIN BOARD ALTERNATE 20 PIN HEADER ey 20 POSITION TERMINAL STRIP LED 19X1604 I J14 P3 T 2 2 ty ORCH SWITCI I TORCH SWITCH 8 I I Gc I 4052643 OK TO MOVE GAS OPTIONAL 31 8 INTERFACES alta 0 DIVIDED OUTPUT l 9 9 2 8 8 3 ADAPTER HARNESS USED 1 1 i REMOTE CURRENT CONTROL WHEN REMOTE CURRENT H 25 55 CONTROL IS USED WITH 2 2 BC common 4 4 7 COMMON AUTOMATION mie 3 3 12vDC 3 3 REPLACES CONNECTIONS TEA 4 sw 212 FROM J27 TO J14 15116 TORCH SW 111 9 9 ARC HOLD OHMIC SENSE RELAY ARC HOLD ARC HOLD RETURN CPC HOUSING le T E 4 FE TORCH 159 MOVE oT se OUTPUT INDUCTOR Ezy EG 63 8 zy LOGIC COMMON 9 arc votTs cac I s Ur ae m S __ m __ EN Ce
11. Art A 00306 OL Reverse Bias Diode Not Conducting De VR COM A H m Cathode 1 0 Testing Diode Reverse Bias TROUBLESHOOTING 7 8 If a diode checks bad replace the diode module Reconnect all cables C Diode Module Board Tests A Disconnect primary power at the source before tak ing any resistance checks 1 Input Diode Module Board Circuit Test For 208 230 Volt Power Supplies Indication can be twice other indications a Remove AC power Refer to Appendix 5 A or 5 B Main PCB Wiring diagram c The meter should indicate a diode drop in one di rection and an open in the other direction for each b Check Input Diode for shorted input diode With check Replace the Input Diode Module Board if an ohmmeter set on the diode range make the fol the readings do not match the chart lowing checks from Main PC Board to Input Di ode d IfInput Diode Module Board is shorted make the following checks with an ohmmeter at the Main For 400 Volt 415 Volt 460 Volt and 600 Volt Power Contactor W1 Supplies 400V 415V 460V and 600V If any test has resistance then replace the Main Con bactor 2 Output Diode Module Board Circuit Test a Use ohmmeter set on the diode function and make the following measurements on the Output E3 Open Diode Module Boards to Power Output PC Board Indication can be twice other indications Output Diode A Output Diode
12. OUT SENSE TORCH MOUNTED GAS SOLENOID CURRENT SENSE CURRENT SENSE J24 P24 GAS CURRENT SENSE RTN F2 0 9A SOLENOID CURRENT SENSE RTN RESETABLE DC COI EX 1 2 F AUS COM PRESS GOOD 1 ISENSE 3 MAIN BOARD a SWITCH 5 ASSY 19X1930 EY 1 CLOSED WHEN TIP VOLTS ASSY 19X2228 415V PRESSURE OK assy wxwrs ASSY 19X1929 460V wi MAIN x WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED CONTACTOR SOL1 IS POWERED BY T6 ONLY SOL2 POWERED BY P24 1 2 Art A 07152 1 2 3 4 5 APPENDIX A 20 Manual 0 2957
13. C21 921 R43 R85 H3 D4 R86 9000 TP2 M Ree R72 ae R73 Re TP1 652 R90 241 psi RI RI 00000000000000000 TP9 TPS FF TP10 9 895
14. 1 2 3 4 5 T wi E12A 1 208 230V E5 2 DRIVE J3A 1 PHASE INPUT L2 M Bi E13 E18 A L3 w1 3 14 wi INPUT DIODE 78 ASSY 19X2073 IGBT BOARD ASSY 19X1756 COPPER STRAP E7 CHASSIS FILTERING GND w e 1 2 5 15 B 4 R30 AA 0 ohm M1 F1 FAN1 P15 6 10A 600V 7 1 5 an IGBT BOARD 1 ASSY 19X1756 e 6 5 28VAC 28 16 M2 FAN2 P18 1 28VACB 21 2 1 2BVAC A 122 1 2 sw 72 28 28VAC B TO BIAS SUPPLY 71 P30 oS mm 7 2 swi 8 RUN 1 25 MODE SW dser 2 RAROFF lt 9 PILOT PCB F9 SW2 gt CURRENT ADJUST ES 152 20 80 FOR 101 E6 751 20 60 FOR 81 papas qo 1 59 1 1 Por HiGH E10 dead HER CURRENT a Ba 51 CONTROL 5 Haat 5 AG MAIN TRANSFORMER LED PCB 5 8 SAS 7 Hy 7 19X1604 8 8 Dc D CURRENT SENSE P29 IGBT 2 HEATSINK 3 TEMP AATA 4 6 P32 2 52 47 INDUCTOR J33 P33 P39 139 OUT sENSE 7 11 72 1H DC 2 2 72 2 2 LOGIC CSR 5 5 1 5 5 ASSY 19X1913 CM104 12vbc TT1 1 1SENSE 6 6 6 6 ASSY 19 2285 101 12 95 1 2 7 7 7 ASSY 19X1932 CM81 DC COM 3 3 3 TIP VOLTS 8 8 8 8 ASSY 19 2284 81 DC COM 4 4 1 T ATC CONNECTION SON S 55 CONFIGURATION RUN SET 7 7 1 CONTACTOR ON 134 P34 STANDARD PRESS GOOR 8 E RING 502 7 77 inv p13 oio 0 PP 2 2
15. To MAIN PCB ASSEMBLY 19 1929 4607 19 1912 208 250 19X1930 400 600V Art A 03653 Heat Sink To Input Temp Sensor Contactor p If installed in conjuction Automation Interface Board is not installed in all units with Automation Interface PC Board Manual 0 2957 A 7 APPENDIX APPENDIX 6 LED POT PC BOARD LAYOUT J14 ANN 04 RE O J14 C m FO A gt f D5 oot lo oem R5 Lo R1 R4 o Of oof P9 Ol OT ro 9 R2 R3 D7 A 03712 Pot LED PC Board Signals J14 1 from Main PC Board J27 1 Pot High J14 2 Main PC Board J27 2 Pot Wiper J14 3 from Main PC Board J27 3 Pot Low 14 4 12vdc 27 4 J14 5 Logic Low Signal for AC OK Indicator from Logic PC Board J27 5 J14 6 Logic Low Signal for GAS Indicator from Logic PC Board J27 6 J14 7 Logic Low Signal for TEMP Indicator from Logic PC Board J27 7 J14 8 Logic Low Signal for DC Indicator from Logic PC Board J27 8
16. 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 op erator or others in the workplace Never touch any parts that are electrically live or hot GENERAL INFORMATION Wear dry gloves and clothing Insulate yourself from the work piece or other parts of the welding circuit Repair or replace all worn or damaged parts 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 Publica tions Disconnect power source before performing any service or repairs Read and follow all the instructions in the Operat ing Manual Ay AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the plasma arc Be sure there is no combustible or flammable ma terial 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 Provide afire 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 under water or while using a water table DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminate
17. iisas 1 1 1 01 Notes Cautions and Warnings pp 1 1 1 02 Important Safety Precautions a eene 1 1 1 03 Publications it 1 2 1 04 Note Attention et Avertissement pp 1 3 1 05 Precautions De Securite Importantes pp 1 3 1 06 Documents De Reference Ne 1 5 1 07 Declaration of Conformity 1 1 0 1 7 1 08 Statement of Warranty nennen nnne nnne 1 8 SECTION 2 INTRODUCTION eet rte rere b ee be 2 1 2 01 Scope Of Manual iii 2 1 2 02 General Service Philosophy ss 2 1 2 03 Service Responsibilities pp 2 1 SE GTION3 DESCRIPTION trei ana 3 1 9 01 SCOPC 3 1 3 02 Power Supply Specifications pp 3 1 3 03 Air Regulator Filter Assembly Specifications 3 3 4 TROUBLESHOOTING 4 1 4 01 IritrodUctlOn iid enn 4 1 4 02 Periodic Inspection amp Cleaning Procedures 4 1 4 03 System Theory eit Been in dash ie Dent 4 1 4 04 Common Operating Problems pp 4 2 4 05 Troubleshooting Guide General 4 3 4 06 Circuit Fault Isolation nennen nnne nnn 4 4 4 07 Main Input and Internal Power Problems pp 4 5 4 08 Pilot Arc Problems oriri o asi rte hanes 4
18. DA Front Panel AC Indicator D5 Front Panel TEMP Indicator D6 Front Panel GAS Indicator D7 Front Panel DC Indicator APPENDIX A 8 Manual 0 2957 APPENDIX 7 INPUT DIODE PC BOARD LAYOUT E18 213 5 1 90 INPUT DIODE 19x1811 JO 9 iD Md CEOs 1 1 Um E Aes Art A 03703 Manual 0 2957 A 9 APPENDIX IGBT CIRCUIT PC BOARD LAYOUT APPENDIX 8 E21B E9B EL ne f 8 E21A E9A E19B 7 J7B 0 E 9 CS oo ve s CAE 922 esas s ar O2 O gt JOO O COO COO 688 be 1491 S vy OO O O ase P o 12 13 va no O 1
19. TP11 fom H4 TP5 D25 TP8 TP7 Art A 03654 Logic Board Layout TROUBLESHOOTING 48 Manual 0 2957 Gas continues to flow with RUN RAPID AUTO RESTART SET switch in RUN position 1 Damaged gas solenoid a Turn the front panel ON OFF switch to OFF Ifgas continues to flow debris from the air line is preventing the solenoid from closing Clean or replace the solenoid 2 Faulty RUN RAPID AUTO RESTART SET switch a Put switch in SET position Disconnect wire harness connector from Main PC Board recep tacle J18 Check continuity through wire har ness sockets 7 and 8 If no continuity replace switch 3 Faulty Logic PCB a Measure for approximately 12 vdc between P1 7 and TP 1 on the Logic PCB If0vdcis present replace Logic PCB Gas flows continuously when power is turned on AC indicator flashes TEMP indicator off GAS indicator ON DC indicator off Art A 03987 Cc 1 Torch switch is activated closed before user turns power on a Release torch switch turn power supply OFF then ON with torch switch released 2 Faulty torch switch a Turn power supply Disconnect torch from power supply Refer to Appendix Pages for Torch Pin Out Diagrams Check torch switch continuity through sockets 3 and 4 NOTE In mechanized machine torch applications remo
20. 79 6 a GAS ON t1 1 313 55 DRAG ON amp pzs DC OK 2 12 2 ToRcHSWRTN 4 4 111 2 OVTEMP 13 113 3 SOLENOID ON L TORCH SW 8 amp TORCH roe SK 5 TORCH SW 6 NOATCMALE 312 7 777 CONNECTOR cic J23 RECEIVER gt POTLOW 28VAC A ar sita GATE DRIVE RTN PAR aa CONN sm MR GATE DRIVE A A B ractory INSTALLED OPTIONAL OUT SENSE A TORCH MOUNTED GAS SOLENOID CURRENT SENSE r eat CURRENT SENSE P24 GAS CURRENT SENSE F2 09A 8 SOLENOID CURRENT SENSE RIN RESETABLE 1 9 DC PRESS GOOD 3 T ISENSE 5 5 t PRESSURE TIP voLrs 6 MAIN BOARD Pet PE 8 EXTENDER ASSY 19X1912 PRESSURE OK ASSY 19X1775 WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED MAIN CONTACTOR SOL1 IS POWERED BY T6 ONLY SOL2 POWERED P24 1 2 Art A 07153 1 2 3 4 5 APPENDIX A 18 Manual 0 2957
21. cess in the face of the diode Ensure that the washer is under the head of the 5 b Torque hardware to 17 in Ib 1 9 Nm NOTE Belen Failure to torque properly will cause component 12 Re install the Power Supply Cover damage Manual 0 2957 5 9 REPLACEMENT PROCEDURES 9 Connect wires as follows CutMaster 81 Output Diode Connections Output Diode A Output Diode B From Output Diode A Terminals PCB Terminal To Power Output PCB Terminal To Power Output From Output Diode B Terminals E34 E39 E34 E39 E48 E50 E48 E50 E58 E56 E60 E57 E53 E54 E53 E54 E Output Power PC Board Replacement Follow the antistatic procedures in subsection 5 02 1 2 REPLACEMENT PROCEDURES Remove cover per subsection 5 04 A Locate the Power Output PC Board mounted to the Heatsink Shroud Carefully remove all wire connections to the Out put Diodes Straighten the Output Diode wires to be perpen dicular to the Output Power PC Board Label then disconnect all other wire connections to the Output Power PC Board Refer to Appen dix 10 for output power PC Board wiring details Remove the bolts at the top left and bottom right corners of the Output Power PC Board O Screw Locations 8 Art A 03166 Lift the Output Power PC Board off its supports and set aside Install the replacement Output Power PC Board by reversing t
22. Cartridges as marked Art A 02942 Two Stage Filter Kit Catalog 7 7507 9 7740 9 7741 9 7742 7 7500 9 7535 9 7527 9 1021 9 1022 9 8529 9 8331 9 7072 Manual 0 2957 PATENT INFORMATION The following parts are licensed under U S Patent No s 5120930 and 5132512 Catalog Number 9 8235 9 8236 9 8237 9 8238 9 8239 9 8244 9 8245 Manual 0 2957 Description Shield Cap Drag 50 60A Sheild Cap Drag 70 100A Shield Cup Body Shield Cap Machine 50 60A Shield Cap Machine 70 100A Shield Cap Drag 40A Shield Cap Machine 40A 6 9 PARTS LISTS This Page Left Blank PARTS LISTS 6 10 Manual 0 2957 APPENDIX 1 INPUT WIRING REQUIREMENTS CutMaster 81 Input Wiring Requirements Suggested Sizes See Notes Was Freq 1 Ph 3 Ph 1 Ph 3 Ph Fuse Amps Wire AWG Wire Canada Vot tPh 3Ph camps ames 5060 118 57 _5060 118 108 M L6 6 6 L 9 o2 L d9 j t L j 49 p e ____ o ___ ESS En a 08 co ____ 105 Voice with Suggested Circuit Protection and Wire Sizes CE CutMaster Input miring Specifications r e ower Input Current input 9099054 Sizes See Noles Walage Frequency Sn 3Ph Fuse Amps Wie mm Volts Hz Amp 58 3 Ph CODE Line Voltages with Suggested Circuit Protection
23. E62 To Power Output PC Board Terminal E62 NOTES Manual 0 2957 LOT BOARD 19X2086 REV 2 Pin Receptacle J1 E58 Bee Art A 03881 Pilot PC Board with receptacle J1 may replace PC Board without receptacle J1 Receptacle J1 is used only in automated applications A 13 APPENDIX APPENDIX 12 28VAC CIRCUIT DIAGRAM Line Voltage Auxiliary Transformer Voltage Protection 12 Regulator 03710 Main Power PC Board APPENDIX A 14 Manual 0 2957 APPENDIX 13 DATA TAG INFORMATION of Power Supply Note 1 IHERMAL DYNAMICS X A THERMADYNE Company Date of Mfr West Lebanon NH USA 03784 Made in USA AC Output Current Type Duty Cycle Factor Manufacturers Name and or Logo Location Model and Revision Level Serial Number and Production Code Regulatory Standard Covering This Type of Power Supply Output Range Amperage et p ge Amperag i Voltage Plasma Cutting Symbol x Duty Cycle Data Note 3 Uo U2 Rated No P Conventional Load Voltage Load Voltage Rated Maximu
24. Gas ON Logic Low DC OK Logic Low OVTEMP Logic Low AC OK Logic Low Torch Switch Logic Low Torch Switch Return Logic Low 12vdc Logic Low Pot High Logic Low Pot High Pot Low Gate Drive B Return Gate Drive B Gate Drive A Return Gate Drive A Out Sense Current Sense 0 2957 TP6 D33 c29 040 032 R85 H3 558 c35 ig i i R43 e pse R70 c Pi 055 OF SON R87 g7 P1 7 Reg 236 94 t45 R89 Q c52 e P1 9 c56 RIS 1 2 D41 ps a R96 1 R 7 OL 898 OL R92 RIF TP nj 6 LT TP9 c 9 TP10 1 uio R93 s OZ TP1 1 55 2 H4 TP8 TP7 Art 03654 P1 27 Current Sense P1 28 Current Sense Return P1 29 Current Sense Return 1 30 DC Com 1 31 DC Com P1 32 Not Used 1 33 ISense P1 34 Not Used P1 35 Not Used P1 36 TipVolts INDICATORS D13 INV ON D25 DRAGON D33 SWITCH ON TEST POINTS TP 1 Common TP 2 Current Demand Signal TP 3 Converter Enable TP 4 CSR Logic Low TP 5 Not used TP 6 Fault Logic Low 7 DC OK Logic Low TP 8 Sense TP 9 Current Sense TP 10 Gate Drive A TP 11 Gate Drive B A 3 APPENDIX APPENDIX 4 MAIN POWER PC BOARD LAYOUT
25. NY 10018 1 04 Note Attention et Dans ce manuel les mots note Avertissement attention et avertissement sont utilis s pour mettre en relief des informations caract re important Ces mises en relief sont classifi es comme suit NOTE Toute op ration proc dure ou renseignement g n ral sur lequel il importe d insister davantage ou qui contribue l efficacit de fonctionnement du syst me Manual 0 2957 mmm ATTENTION Toute proc dure pouvant r sulter l endommagement du mat riel en cas de non respect de la proc dure en question SSEMENT Toute proc dure pouvant provoquer des blessures de l op rateur ou des autres personnes se trouvant dans la zone de travail en cas de non respect de la proc dure en question 1 05 Precautions De Securite Importantes SSEMENTS L OP RATION ET LA MAINTENANCE DU MAT RIEL DE SOUDAGE L ARC AU JET DE PLASMA PEUVENT PR SENTER DES RISQUES ET DES DANGERS DE SANT Coupant l arc au jet de plasma produit de l nergie lectrique haute tension et des missions magn tique qui peuvent interf rer la fonction propre d un pacemaker cardiaque les appareils auditif ou autre mat riel de sant electronique Ceux qui travail pres d une application l arc au jet de plasma devrait consulter leur membre professionel de m dication et le manufacturier de mat riel de sant pour d terminer s il existe des risques de sant Il
26. square than the left TROUBLESHOOTING E Dross 4 2 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 nar row 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 Parts In Place Circuit The power supply connects to Models SL60 or SL100 Torches Parts In Place circuitry in the power supply checks for the presence of torch consumable parts in the torch head When the shield cup is properly in stalled there is a slight gap between the shield cup and the torch handle Gas vents through this gap as part of normal operation Do not attempt to force the shield cup to close this gap Forcing the shield cup against the torch head or torch handle can damage torch components Common Cutting Faults Insufficient Penetration a Cutting speed too fast b Torch tilte
27. 11 4 09 Main Are Problems toi te ct etd tud edes pi dee cs 4 14 4 10 Test Proc dures itt erento pe et eerie te et 4 15 SECTION 5 REPLACEMENT PROCEDURES Ne 5 1 5 01 SCOPE ie iu ord ite AM AA e E ta a a o Mt d sos 5 1 5 02 Anti Static Handling Procedures pp 5 1 5 03 Parts Replacement General Information ppp 5 1 5 04 Major External Parts Replacement pp 5 2 5 05 Front Panel Parts 5 3 5 06 Left Side Internal Parts Replacement pp 5 4 5 07 Rear Panel Parts Replacement pt 5 7 5 08 Right Side Internal Parts Replacement 5 8 TABLE OF CONTENTS continued SECTION 6 PARTS LISTS ep epe eem eve elie uu ea SEE ER ete eine 6 1 6 01 Introd ction es cece ec even tco dye eee eek Ea ete rr ee ek 6 1 6 02 Ordering Information eene nennen nnns 6 1 6 03 Major External Replacement Parts pp 6 2 6 04 Front Panel Replacement Parts 6 3 6 05 Left Side Internal Component Replacement Parts 6 4 6 06 Rear Panel Replacement Parts pp 6 6 6 07 Right Side Internal Component Replacement Parts 6 7 6 08 Options and Accessories Ne 6 8 PATENT INFORMATION fros tia oot terne Feed pee edere e edet ieee tees 6 9 APPENDIX 1 INPUT WIRING REQUIREMENTS iii A 1 APPENDIX 2 SEQUENCE OF OPERATION BLOCK DIAGRAM 2
28. 4 APPENDIX A 22 Manual 0 2957 6 r 9 10 COMP DESCRIPTION LOCATION FUSE 3 10A 600V FNO R FUSE 0 9A RESETABLE OUTPUT INDUCTOR FAN 4 5 220VAC FAN 4 5 220VAC PRESSURE SWITCH GAS SOLENOID A SWITCH ON OFF SWITCH RUN SET RAR MAIN TRANSFORMER TEMP SENSOR IGBT HEATSINK TEMP SENSOR INDUCTOR MAIN CONTACTOR NOTES UNLESS OTHERWISE SPECIFIED 1 DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS IS FOR REFERENCE ONLY OPTIONAL AUTOMATION INTERFACE CONNECTIONS B PLUGS INTO J27 ON MAIN BOARD ALTERNATE 20 PIN HEADER 22 MEME 20 POSITION TERMINAL STRIP LED 19X1604 J14 P3 1 111 47 1 a 313 2 I Gc 55 20 1919 TORCH SWITCH 1 I 818 19X2041 18 18 8 8 OPTIONAL 16 16 amp GAS AUTOMATION 15 15 OK TO MOVE INTERFACE 14 14 13 13 222 D o 12 12 4111 DIVIDED OUTPUT ADAPTER HARNESS USED P1 10 10 WHEN REMOTE CURRENT CSR TSR 8 5 CONTROL IS USED WITH 2 2 DC common AUTOMATON 52 Fravoc t RE
29. Check connector pins 1 and 2 for at least 12K ohms resistance is less than 12K ohms replace output inductor L1 If temp switch is open replace Main PC Board 5 Faulty Main PC Board a Check for 12 vdc on Main PC Board between TP4 and 1 If 0 vdc is present replace Main PC Board 6 Faulty Fan s Measure for 280VAC on Main PC Board from J15 1 toJ15 5 and from J15 2 to J15 6 f voltageat 15 1 to 15 5 is correct replace upper fan M1 e f voltage at 15 2 to J15 6 is correct replace lower fan M2 Manual 0 2957 D Gas flows AC indicator and GAS indicators 2 Oil moisture in air lines ON TEMP indicator off DC indicator a Put the ON OFF switch in the ON up posi tion Putthe RUN RAPID AUTO RESTART off or blinks on off once SET switch in the SET down position b Place a welding filter lens in front of the torch A and turn on the air Any oil or moisture in the air will be visible on the lens Do not start an we arc c Purge system If problem corrected add filters de res E 3 Incorrect torch parts Art A 03991 556 Inspectthe torch parts replace as needed Fa 4 Faulty leads 1 Faulty IGBT or Output Diode Module Assembly s 5 Faulty torch a Check torch 6 Faulty connection of wire 58 or 62 to Pilot Board a Check per Subsection 4 10 C repair as needed 2 Faulty Ma
30. DE COUPE ET DE SOUDAGE L ARC ET AU GAZ disponible aupr s du Superin tendent 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 TRA VAIL ET DANSLES ECOLES disponible de l Institut Am ricain des Normes Nationales American Na tional Standards Institute 1430 Broadway New York NY 10018 5 Norme ANSI 741 1 NORMES POUR LES CHAUSSURES PROTECTRICES disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 6 Norme ANSI Z49 2 PR VENTION DES INCENDIES LORS DE L EMPLOI DE PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de l American Na tional Standards Institute 1430 Broadway New York NY 10018 7 Norme A6 0 l Association Am ricaine du Soudage AWS LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERM DES PRODUITS COMBUSTIBLES disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Am ricaine pour la Pro tection contre les Incendies LES SYST MES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCI S disponible aupr s de la Na tional Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 GENERAL INFORMATION 9 Norme 70 de la NFPA CODE ELECTRIQUE NA TIONAL disponible aupr s dela National Fire Pro tection Association Batterymarch Park Q
31. LI L1 D RECEIVER y MALE CONNECTOR E64 E64 E35 E62 CSR NEG E49 E45 E35 E61 E3 E1 E62 E43 E32 OO PILOT E64 CSR Vo CURRENT SENSE JUMPER 1 E37 58 E36 E57 E58 E C1 MODE SW OUTPUT DIODE OUTPUT DIODE E345 RAR OFF 52 ASSEMBLY ASSEMBLY 61 2 19 1757 J40 P40 12 1 1 a 2 2 E50A 313 46 5 5 020 ap 5 ISENSE 8 8 18 N28 PILOT BOARD ASSY 19 2157 CHASSIS E63 THRU SCREW TERMINAL GND Rev Revisions By Date PCB No 1 101136 REL DLL oso703 ZHHERMAL DYNAMICS NE No 101314 HAS 02 11 04 ae WEST LEBANON NH Scale DC COMMON DC COMMON Eco 101428 THERMADYNE Company 92989 AD ECO 101614 HAS 03 22 05 information Proprietary to THERMAL DYNAMICS CORPORATION 05 07 03 POWER OUTPUT BOARD ASSY 19X1914 PE eco eee eee ME _ AF ECO Bote RWH 01 27 06 NOTE Uniess omewise speclfed Resistors ar in Ohms 14W 5 Capacitors aro in Microfarads UF per en of TITLE SCHEMATIC OWG Ne Si el ei wes CM81 101 208 230V SYSTEM D 42X1136 6 7 8 9 10 Art A 07153 Manual 0 2957 A 19 APPENDIX APPENDIX 16B SYSTEM SCHEMATIC 400 Volt 415 Volt and 460 Volt Units E6 E12A E17A GATE DRIVE 208 230V 415 400V
32. Z wi 460 12 0 E13 A 3 PHASE INPUT EZ E18 E14 E19A E21A INPUT DIODE ASSY 19X2073 IGBT BOARD ASSY 19X1756 400V 3 PHASE INPUT E12B GATE zin DRIVE J3B FILTERING 400V CE VERSION INCLUDES IN LINE 6 B EMC FILTER R29 415 460 600V R78 400V R30 208 230V M1 FAN1 E19B E21B 28VACB 28VAC A IGBT BOARD ASSY 19X1756 own SEE TABLE 1 FOR F1 R29 R30 amp R78 M2 FAN2 J31 28VACB 28VAC A 2 3 SW1 26 RUN J25 P25 MODE SW 5 1 46 SET PROT ARC HOLD E34 F9 SW2 28VACA E36 28VACB E35 5 152 E6 751 28 28VAC B TO BIAS SUPPLY J30 1 P30 G ON OFF SW CERCLE gt CURRENT ADJUST 20 80 FOR 101 20 60 FOR 81 J27 POT HIGH POT WIPER LOW 12V AC GAS OVERTEMP DC LA y N N g
33. for each cause A Repairas needed being sure to verify that unit is fully operational after any repairs NOTES Many signals are transferred between Printed Cir cuit Board Assemblies on Cables If these cables become faulty they can then cause various prob lems Do not forget about these cables when troubleshooting While troubleshooting visually inspect the internal components for signs of overheating fractures and damage 4 3 TROUBLESHOOTING 4 06 Circuit Fault Isolation B Initial Setup Conditions A Controls and Indicators This section is to help isolate the defective circuit before 2 40 9 20 TRA troubleshooting identify symptoms and test the unit for proper operation Follow the instructions as given to iden tify the possible symptom s and the defective circuit After repairs are complete run the following tests again to verify that the unit is fully operational 1 2 Connect gas supply to rear of Power Supply Turn on gas supply and set operating pressure per pressure setting label on power supply 60 p NOTE Minimum gas pressure for power supply operation C CT gt is lower than the minimum for torch operation Te 2 3 Set Power Supply controls as follows J ON OFF switch to OFF Down Art A 03845 ON OFF switch This switch controls AC power to the unit Up is ON down is OFF RUN RAPID AUTO
34. screws securing the PC Board to the Center Chassis Screw locations 5 9 0 9 Art A 03165 Carefully remove the original PC Board from the unit Transfer the Logic PC Board standoffs to the re placement Main PC Board Install the replacement PC Board by reversing the steps above It may be easier to install the PC Board if the Power Supply is turned on its right side first Refer to the charts in subsection 5 06 D for input diode and IGBT wiring connection points EMI Filter Replacement CE Units only 1 Label the input power cable connections and the cable connections to the main input contactor Disconnect all wire and cable connections to the EMI Filter Remove the hardware securing the EMI Filter This hardware passes upward through the base of the power supply Put the replacement EMI Filter in position and secure it with the hardware removed in Step 3 Manual 0 2957 5 Connectthe input power cables and the cable con B nections to the main input contactor 6 Re install the Power Supply cover 7 Test the Power Supply for proper operation 5 07 Rear Panel Parts Replacement Refer to subsection 6 06 for parts list and overall detailed drawing C G Disconnect primary power from the source before opening or disassembling the power supply A Filter Regulator Assembly Replacement G D Disconnect the gas supply at the source and blee
35. tainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PRO CESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Associa tion Batterymarch Park Quincy MA 02269 NFPA Standard 51B CUTTING AND WELDING PRO CESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 CGA Pamphlet P 1 SAFE HANDLING OF COM PRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 CSA Standard W117 2 CODE FOR SAFETY IN WELD ING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Associa tion 1900 Arch Street Philadelphia PA 19103 American Welding Society Standard AWSF4 1 RECOM MENDED SAFE PRACTICES FOR THE PREPARA TION FOR WELDING AND CUTTING OF CONTAIN ERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 ANSI Standard Z88 2 PRACTICE FOR RESPIRATORY PROTECTION obtainable from American National Standards Institute 1430 Broadway New York
36. tection Make sure no part of the operator s body comes into contact with the workpiece while the torch is activated Sparks from the cutting process can cause damage to coated painted and other surfaces such as glass plastic and metal Handle torch leads with care and protect them from damage A Piloting Piloting is harder on parts life than actual cutting be cause the pilot arc is directed from the electrode to the tip rather than to a workpiece Whenever pos sible avoid excessive pilot arc time to improve parts life 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 Edge Starting For edge starts hold the torch perpendicular to the workpiece with the front of the torch tip at the edge ofthe 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 Direction of Cut The plasma gas stream swirls as it leaves the torch The purpose of the swirl is to maintain a smooth col umn of gas The swirl effect results in one side of a cut being more square than the other Viewed along the direction of travel the right side of the cut is more
37. 2 for 400 Volt 415 Volt 460 Volt and 600 Volt Power Supplies 9 8554 3 1 Connector PCB 9 8576 4 1 PCB Assembly Logic Board for Non Mechanized units 9 7992 4 1 PCB Assembly Logic Board for Mechanized units 9 9440 5 1 PCB Assembly Kit IGBT Circuit for 208 230 Volt 400 Volt 415 Volt and 460 Volt Power Supplies 9 8578 IGBT PCB Round Thermal Pad for 600 Volt Power Supplies 9 8646 IGBT PCB Round Thermal Pad 6 1 PCB Assembly Kit Input Diode 9 7088 Input Diode PCB Rectangular Thermal Pad 7 1 PCB Assembly Main Power for 208 230 Volt Power Supplies 9 7986 for 400 Volt Power Supplies 9 7990 for 415 VoltPower Supplies 9 8669 for 460 Volt Power Supplies 9 7989 for 600 Volt Power Supplies 9 7991 8 1 EMI Filter Kit CE Power Supplies only 9 7667 PARTS LISTS 64 Manual 0 2957 NOTE Illustration may vary slightly from unit PARTS LISTS 6 5 Manual 0 2957 6 06 Rear Panel Replacement Parts Item Qty 1 1 2 1 3 1 4 1 1 1 1 1 5 1 6 1 Description Ref Assembly Filter Regulator Regulator Filter Replacement Element Regulator Mounting Bracket Input Power Cable for 208 230 Volt Units for 400 Volt Three Phase units for 400 Volt and 415 Volt CE units for 460 Volt Three Phase units for 600 Volt Three Phase units Mounting Nut Pressure Gauge Art A 03005 NOTE Illustration may vary slightly from unit PARTS LISTS Catalog 9 7514 9 4414 9 7589 9 8596 9 8562 9 8553 9 859
38. 3 9 8593 9 5804 9 1045 Manual 0 2957 6 07 Right Side Internal Component Replacement Parts Item Qty Description Ref Catalog 1 1 Assembly Pressure Switch Solenoid Ps1 9 8329 2 1 Assembly Pilot Board 9 8337 1 Fan 220V 115 9 7687 4 1 Assembly Main Transformer T5 for 208 230 Volt units 9 8589 for 400 Volt and 415 Volt units 9 8603 for 460 Volt units 9 8584 for 600 Volt units 9 8635 5 1 Assembly Output Inductor L1 9 8591 6 1 Assembly Output Power PCB 9 7988 7 1 Assembly Output Diode PCB 9 8580 1 Round Thermal Pad Heatsink Shroud Output Diode Heatsink Art 03718 NOTE Illustration may vary slightly from unit Manual 0 2957 6 7 PARTS LISTS 6 08 Options and Accessories Oty Description Single Stage Filter Kit Includes Filter And Hose Replacement Filter Body Replacement Filter Element Replacement Filter Hose NotShown Bracket Filter Mounting DualStage Air Filter Assembly Replacement First Stage Cartridge 1 1 1 1 1 Two Stage Air Line Filter Kit Includes Hose amp Mounting Screws 1 1 1 1 Replacement Second Stage Cartridge Not Shown 1 Extended Work Cable 50 ft 15 2 M 1 Wheel Kit 1 Nylon Canvas Power Supply Dust Cover Housing Filter Element Cat No 9 7741 M O ring Cat No 9 97743 Assembled Filter Cover 5 Barbed a Fitting Jg Art A 02476 Single Stage Filter Kit PARTS LISTS First amp Second Stage
39. 91912 208 230 191930 4007 19 1931 6004 mo Art A 03652 Heat Sink 2 To Input 2 To Input Temp Sensor Contactor Contactor installed in conjuction with Automation Interface Board is not installed in all units Automation Interface PC Board APPENDIX A 6 Manual 0 2957 APPENDIX 5B MAIN PC BOARD WIRING LAYOUT 400 Volt 415 Volt 460 Volt and 600 Volt Units To Inductor Temp Sensor To Power Output Board To Press Switch Solenoid Contactor To Heat Sink LT1 Test To On Off and To Chassis Connector Run Rapid Restart Ground To Main To Torch Set Switches To Fans Input Contactor Connector ze REN Z 1 10 Auto Interface Board J1 5 15 I M ra Celle QE Auto Interface 2 gi Secondary H Board J1 6 E e mee een Transformer 27719 POT LED e or to Optional Remote Current Control Logic Board via Connector INPUT Lol DIODE 3 055559499999995555999999999999999998
40. B Meter Meter Meter Mer Diode Drop E57 E49 Diode Drop Indication can be twice other indications b Themeter should indicate a diode drop in one di rection and an open in the other direction for each check Replace the Output Diode Module Board s if the readings do not match the chart TROUBLESHOOTING 4 16 Manual 0 2957 3 IGBT Module Board Circuit Test a Use ohmmeter set on the diode function and make the following measurements on the IGBT Module Board s to the Main PC Board Meter Meter Meter s Meter CE E27 E23 30 23 E4 10 20 10 20 E4 D D E20 E4 E30 E23 Diode Drop Indication can be twice other indications b Themeter should indicate a diode drop in one di rection and an open in the other direction for each check Replace IGBT Module Board s if readings are not the same as the chart TP4 TP2 D13 D Main Input Power Test A WARNING The following tests must be performed with the power supply connected to primary input power There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair without proper training in power electronics measurement and troubleshooting tech niques wu Reconnect power and observe proper start up procedure AC indicator on the Front Panel should be ON If indicator is OFF there isno voltageto the Power Supply or over
41. ES 5 2 Manual 0 2957 5 05 Front Panel Parts Replacement C RUN RAPID AUTO RESTART SET Switch Replacement Refer to Section 6 04 for Front Panel Replacement Parts and overall detailed drawing A WARNING Disconnect primary power from the source before opening or disassembling the power supply A Current A Control Knob Replacement 1 Turn the control knob fully clockwise and note the location of the pointer on the knob 2 Loosenthe screw securing the Knob to the poten tiometer shaft and remove the Knob 3 Placethe replacement Knob on the potentiometer shaft with the location of the pointer the same as noted in step 1 4 Tighten the screw to secure the knob to the po tentiometer shaft B ON OFF Switch Replacement 1 Remove the cover per subsection 5 04 A 1 2 3 2 Disconnect the wires on the rear of the ON OFF 5 02 Switch Note the location of each wire as shown below Top clip Wire 21 Wire 22 Wire 24 Wire 23 Art A 02774 3 Squeeze together the clips on the top and bottom of the Switch Remove the Switch through the Front Panel 4 Install the replacement Switch by reversing the above steps Manual 0 2957 5 3 1 2 3 Remove the cover per subsection 5 04 A Disconnect the wires on the rear of the Switch Note the location of each wire as shown Art A 03906 Squeeze together the clips on the top and bottom of theSwitch then remove t
42. IHERMAL DYNAMICS 1 CUTMASTER PLASMA CUTTING SYSTEM Rev AC 01 Date April 13 2007 Operating Features Manual 0 2957 208 60 Be pon Le Read and understand this entire Manual and your employer s safety practices before installing operat ing 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 Power Supply CutMaster 81 Operating Manual Number 0 2957 Covered under U S Patents Published by Thermal Dynamics Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermal dynamics com Copyright 2003 2004 2005 2006 2007 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Printed in the United States of America Publication Date April 13 2007 Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial Torch Serial SECTION 1 TABLE OF CONTENTS GENERAL INFORMATION Z S au a hs usa nne
43. MOTE CURRENT CONTROL 1 REPLACES CONNECTIONS 152 5 5 sw 51 5 1 FROM 427 J14 4 4 DC COMMON 7 LAC ex 2 2 1 8 244 _ CPC I HOUSING gr 4 Et TORCH T ok MOVE T 61 8 EE sen ET 8 Ee LOGIC COMMON OUTPUT INDUCTOR a 7 ARC voLTs cas U nm noy in ae ae E EX rs 2 L1 D pos ATC RECEIVER MALE CONNECTOR E64 E64 E35 E62 CsR NEG T E49 E45 E35 E E62 E43 E32 R PILOT E64 H JUMPER Y E36 ES WORK E C1 MODE SW RAR OFF OUTPUT DIODE OUTPUT DIODE 52 ASSEMBLY AssEMBLY 948 51 19 1757 19 1757 P40 14 105 E50A 3 46 17 E48A 5 17 7 E53A E53B 09 E54A E548 GHASSISISND ASSY 19X2157 THRU SCREW TERMINAL Rov Revisions By Das gt PCB No RE ou 00708 THERMAL DYNAMICS noms F AB ECO 101314 HAS 02 11 04 2A WEST LEBANON NH Scale Supersedes DC COMMON DC COMMON AG ECO 101429 HAS 06 09 04 A THERMADYNE Company AD ECO 101614 HAS 03222705 formation Propriatary to THERMAL DYNAMICS CORPORATION 05 07 03 POWER OUTPUT BOARD AS
44. NSFORMER LED PCB D 19X1604 CURRENT SENSE IGBT HEATSINK TEMP 1 INDUCTOR 2 E52 E47 J33 P33 T P39 J39 our SENSET 19 pc 2 2 3 2 2 TIP SENSE 3 3 1 315 12VDC 4 4 73 24 ASSY 19X1913 CM101 12vDC TT1 CSR 5 5 77 5 5 ASSY 19X2285 CM101 HE ISENSE 6 6 6 ASSY 19X1932 DC COM 3 3 7 gm 7 7 ASSY 19X2284 CM81 DC COM u 8 CONNECTION TIP SENSE 8 CONFIGURATION RUN SET 7 7 J34 P34 STANDARD 4 RTN 1 1 T 9 9 79 5012 2 2 79 22 B T6 DRAGON Z pes C DCOKI2 12 TORCHSwRTN 4 80 1411 2 13 13 SOLENOID ON TORCHSW 2 81 3L sw 14 14 53 sw TORCH 15 ATC MALE TORCH SWING NM CONNECTOR F1 POT HIGH48 ATC RECEIVER POT WIPER 19 POT LOW 20 28VAC A CH EN enola pen E 28VAC B CONN FACTORY INSTALLED OPTIONAL GATE DRIVE 8011 TORCH MOUNTED GAS SOLENOID OUT SENSE 25 CURRENT SENSE 26 CURRENT SENSE 27 24 GAS CURRENT SENSE RTN 28 F2 0 9A 8 SOLENOID CURRENT SENSE RTN 29 RESETABLE 1 DC EX 2 F pia MAIN BOARD PRESS Goo cli PRESSURE 3 6 ASSY 19X1931 i PS1 d 8 CLOSED WHEN EXTENDER PRESSURE OK ASSY 19X1775 LG WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED MAIN CONTACTOR SOL1 IS POWERED BY T6 ONLY SOL2 POWERED BY 24 1 2 Art A 07151 1 2 3 4 5
45. RESTART SET switch This switch controls gas flow to the torch Up is RUN for general torch operation Center position is RAPID AUTO RESTART for an uninterrupted restart when cutting expanded metal or in gouging or trimming op erations Down is SET for setting gas pressure and purging lines Current control knob A This control regulates cur rent to the torch At output settings over 40 amps cir cuitry in the power supply automatically reduces out put current to 40 amps if the torch tip contacts the workpiece AC indicator When lit indicates operating power is present in the unit TEMP indicator turns on when internal sensors detect temperatures above normal limits GAS indicator Indicates adequate gas pressure for power supply operation NOTE Minimum gas pressure for power supply opera tion is lower than the minimum for torch opera tion DC indicator Indicates DC power output circuit is active Torch must be activated TROUBLESHOOTING 3 RUN RAPID AUTO RESTART SET switch to SET Down CURRENT control A to maximum Main Input and Internal Power Tests Connect main AC power to the unit SetthePowerSupply ON OFF switch to ON up and note the following AC indicator is steady ON Main PCB Relay energizes pulling in main input contactor W1 TEMP Indicator is OFF GAS Indicator is ON if input pressure is suffi cie
46. SSEMBL 9 36 3 9 all E32 Diode A E36 o I Output I Q Inductor To m 5 di unc m Die KO C ce Board e y C PT A TEE 3 42 gk Ac E45 e SEC N e 4 Oye Lim S HET To Trans E64 former e ESB N E49 a 2 57 e qi 49 To Torch exe Le ly E le E64 EAS LA a Trans i E T E61 e re former TORCH Y el 9 WORK M E43 To Output Art A 03655 inductor E58 E52 Work Cable E61 E57 APPENDIX A 12 Manual 0 2957 J28 _ APPENDIX 11 PILOT PC BOARD LAYOUT N ei a 2 5 m e 8 mm R16 1 5 Ul 2 E z ems mos mm le tex ge 9 e e e Wm mim 3 a P m 52 258 35 E m 58 E62 PILOT BOARD 1911905 REV Receptacle 58 E62 CD PC Board Signals 28 1 12 vdc 28 2 DC Com J28 3 Not Used J28 4 Not Used J28 5 Logic Low CSR J28 6 Not Used 28 7 Not Used J28 8 Not Used E58 To Power Output PC Board Terminal E58
47. SY 19X1914 AE ECO 101664 03 24 05 Not For Release Reproduction or Distribution without Written Consent AF Eco RS 0100 08 Unless Otherwise Sr Resistors are in Ohms 1 4W 5 D Lilja 8016 RWH 01 27 06 Capacitors are in Microfarads UF App Sheet Eco 8077 07 31 06 tof 1 s ma SCHEMATIC Sie Ne dish Fay CM81 101 600V 3PH SYSTEM D 42X1134 6 7 9 10 Art A 07151 Manual 0 2957 A 23 APPENDIX Cover Date 5 5 04 6 23 04 6 23 05 4 28 06 9 29 06 3 14 07 4 13 07 APPENDIX Rev AA 01 AB 01 AC 01 APPENDIX 17 Publication History Comments Manual Released Updated system schematics per ECO 101429 Updated 400V systems to include 415V for Australian per ECO101726 Updated per ECO B016 updated schematics added c n for logic board for mechanized units and per ECO 101948 torque spec for replacement input diode Started using new cover styles Added publication history Added patent information and newer rev control Added inside cover information Updated 600 volt schematic to show new fuse Revised C amp Cr revised Troubleshooting section pg 4 12 C 4 5 6 made text corrections revised Section 6 Parts List 6 07 Item 2 Catalog 9 8337 updated Inside amp Rear Cover A 24 Manual 0 2957 IHERMAL DYNAMICS GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA 2800 Airport R
48. UN RAPID AUTO RESTART SET Switch to the SET position Measure for 28 across Solenoid wires 8 and 9 Refer to System Schematic in Appendix Sec tion 28 VAC is present replace Solenoid Pressure Switch Assembly 28 VAC is not present check for 65 psi 4 5 bar at the pressure regulator Check for less than 2 vdc at P1 7 to TP1 on Logic Board Ifless 2 vdc replace Main PC Board Ifmorethan2 vdc replace Logic PC Board Manual 0 2957 F Output Power Tests 1 No DC Output 1 Manual 0 2957 Activate the torch If INV ON indicator D13 on Logic PC Board does not turn ON then replace the Logic PCB If the INV ON indicator D13 blinks ON then OFF immediately perform the following test Turn input power OFF and bleed down the system Attach a 12 wire jumper between the work lead and terminal E35 or E62 on the Output Power PC Board on the right side of the power supply Remove the tip and electrode from the torch A WARNING The following tests must be performed with the power supply connected to primary input power There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair without proper training in power electron ics measurement and troubleshooting techniques The next step will defeat the safety interlock feature Proceed with caution Turn on primary input power and the gas supply Activate the torch swi
49. al notes cautions and warnings are used to highlight important information These high lights are categorized as follows NOTE An operation procedure or background informa tion which requires additional emphasis or is help ful in efficient operation of the system wm CAUTION A procedure which if not properly followed may cause damage to the equipment G A procedure which if not properly followed may cause injury to the operator or others in the oper ating area 1 02 Important Safety Precautions GS OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DAN GEROUS AND HAZARDOUS TO YOUR HEALTH 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 Per sons who work near plasma arc cutting applica tions should consult their medical health profes sional and the manufacturer of the health equipment to determine whether a hazard exists To prevent possible injury read understand and follow all warnings safety precautions and in structions before using the equipment Call 1 603 298 5711 or your local distributor if you have any questions Yau uswa Manual 0 2957 1 1 AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health Keep all fumes and gases from the breathing area Kee
50. and Wire Sizes Based on National Electric Code and Canadian Electric Code NOTES The table above is based on the following output current and voltage 125VDC 40A 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 2957 1 APPENDIX APPENDIX 2 SEQUENCE OF OPERATION BLOCK DIAGRAM ACTION ACTION ACTION ACTION Close external ON OFF switch to ON RUN RUN disconnect switch Rapid Auto Restart SET switch to RUN EE RESULT Rapid Auto Restart RESULT SET switch AC indicator w ON to SET am Power to system Fan s ON amp for most applications 00 or to GAS indicator RESULT Rapid Restart 4 when input pressure is adequate for power supply operation Power circuit ready Gas flows to set pressure for gouging trimming or expanded metal applications RESULT Gas flow s
51. at J15 2 to 15 6 is correct replace up a Check continuity per Fan M2 5 Faulty Gas Solenoid circuit a Test Gas Solenoid circuit per Subsection 4 10 E repair as necessary 6 Faulty Logic Board a Replacelogic board Manual 0 2957 4 7 TROUBLESHOOTING RUN or RAPID AUTO RESTART position AC indicator _ ON TEMP indicators OFF A Av i YE Art A 03986 0 H n n p 1 Gaspressure too low RUN RAPID AUTO RESTART SET switch in GAS a Set operating pressure per pressure setting la bel on power supply D13 2 Faulty Components in Unit Measure for 12 vdc from wire 10 to wire 11 at the Gas Pressure Switch located on the right side of th a e unit If 12 vdc is present and pressure is above 50 psi 3 4 bar replace Gas Pressure Switch Solenoid Assembly Refer to Section 5 08 A If pressure is above 50 psi 3 4 bar and 12 vdc is not present replace the Logic PC Board Remove one wire from the pressure switch Check for 0 vdc at Main PC Board J24 3 to J24 4 from the Logic PC Board Refer to Main PC Board Layout If less than a volt replace Logic PC Board D33 2003 LOGIC PCB ASSY H2 R41 c29 R42 TP4
52. d down the system before attempting this procedure 1 Disconnect the gas input hose from the Filter Regulator Assembly on the Rear Panel of the unit 2 Remove the four bolts securing the Regulator Mounting Bracket to the Rear Panel 3 Disconnect the black gas tube from the Filter Regulator Assembly Adapter Fitting Hold a wrench or similar tool against the locking ring on the Fitting and pull on the tube to release it 4 Remove thenut securing the Filter Regulator As sembly to the Regulator Mounting Bracket Re move the Filter Regulator Assembly from the Mounting Bracket 5 Install the replacement Filter Regulator Assem bly by reversing the steps above When connect ing the gas tube to the Adapter Fitting simply insert the hose into the fitting until fully seated and it will automatically lock Manual 0 2957 5 7 Filter Regulator Bracket Replacement 1 Remove the four bolts securing the Regulator Bracket to the Rear Panel 2 Remove thenut securing the Filter Regulator As sembly to the Regulator Bracket Remove the Bracket from the Filter Regulator Assembly 3 Install the replacement Bracket by reversing the above steps Input Power Cable Replacement 1 Remove the cover per subsection 5 04 A 2 Locate and label the input power cable connec tions and disconnect the cable 3 Unthread the retaining nut on the Input Cable Strain Relief on the inside of the Rear Panel and remove the Input Power Cabl
53. d Layout Ifvoltage goes to 0 vdc replace Output Board Ifnot replace Main PC Board FUSE TP1 U1 J23 5 Faulty Main Input Contactor a Check per Subsection 4 10 D B When operating the amperage drops off after the J24 J34 J32 J29 main cutting arc starts 1 Torch tip contacts workpiece Lift the torch tip off the work At output settings over 40 amps circuitry in the power supply au tomatically reduces output current to 40 amps if the torch tip contacts the workpiece 2 Faulty Pilot Board a With power off and wires E58 and E62 discon nected from the pilot board measure for conti nuity between terminals E58 and E62 If con tinuity is found replace Pilot Board J33 sj 1 m s 1 xa L 353 a em neve MOCCOCCO INPUT DIODE o 4 426 E27 0
54. d or dis sipated Trapped hydrogen gas that is ignited will cause an explosion Aho Noise can cause permanent hearing loss Plasma arc pro cesses can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent per manent loss of hearing To protect your hearing from loud noise wear pro tective ear plugs and or ear muffs Protect others in the workplace Noiselevels should be measured to be sure the deci bels sound do not exceed safe levels e Forinformation on how to test for noise see item 1 in Subsection 1 03 Publications in this manual GENERAL INFORMATION 1 2 PLASMA ARC RAYS 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 To protect your eyes always wear a welding hel met or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to pro tect your skin from the arc rays and sparks Keep helmet and safety glasses in good condition Replace lenses when cracked chipped or dirty Protect others in the work area from the arc rays Use protective booths screens or shields Use the shade of lens as suggested in the following per ANSI ASC Z49 1 Minimum Protective Suggested Arc Current Shade No Sha
55. d too much c Metaltoo thick d Worn torch parts e Cutting current too low f Non Genuine Thermal Dynamics parts used Main Arc Extinguishes a Cutting speed too slow b Torch standoff too high from workpiece c Cutting current too high d Work cable disconnected e Worn torch parts f Non Genuine Thermal Dynamics parts used Manual 0 2957 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 Non Genuine Thermal Dynamics parts used 4 Short Torch Parts Life a Moisture in air source b Exceeding system capability material too thick c Excessive pilot arc time d Gaspressure too low e Improperly assembled torch Incorrect torch parts for the operation Non Genuine Thermal Dynamics parts used 4 05 Troubleshooting Guide General Information A 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 troubleshoot ing techniques LT A General Information This Section covers advanced troubleshooting which re quires power supply disassembly and live measurements Advanced troubleshooting and repair of this unit is a pro cess which should be undertaken only by those familiar with high voltage high power electronic equipment If major complex subassemblies are faulty the faulty
56. de 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 work piece 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 Docu ments U S Government Printing Office Washington D C 20402 ANSI Standard Z49 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding So ciety 550 N W LeJeune Rd Miami FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Govern ment Printing Office Washington D C 20402 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCU PATION AND EDUCATIONAL EYE AND FACE PRO TECTION obtainable from American National Stan dards Institute 1430 Broadway New York NY 10018 ANSI Standard Z41 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the Ameri can National Standards Institute 1430 Broadway New York NY 10018 Manual 0 2957 10 11 12 13 14 15 ANSI Standard 749 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtain able from American National Standards Institute 1430 Broadway New York NY 10018 AWS Standard A6 0 WELDING AND CUTTING CON TAINERS WHICH HAVE HELD COMBUSTIBLES ob
57. dering 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 autho rized Manual 0 2957 6 1 PARTS LISTS 6 03 Major External Replacement Parts Item Qty Description Catalog 1 1 Cover with labels 9 7997 2 Rear Panel provide data tag information when ordering 1 For 208 230 Volt Power Supplies 9 8323 1 For 400 Volt 415 Volt 460 Volt and 600 Volt Power Supplies 9 8322 3 1 Tube roll handle 9 7998 e i Art A 03709 NOTE Illustration may vary slightly from unit PARTS LISTS 6 2 Manual 0 2957 6 04 Front Panel Replacement Parts Item Qty Description Ref Catalog 1 1 Knob Fluted Skirted 0 250 LD 9 8527 2 On Off Rocker Switch DPST 8 3258 3 1 Run Rapid Auto Restart Set Switch 8 3259 4 1 Assembly Pot LED PCB 9 8004 5 1 Cable Work 6 AWG with Clamp 20 Ft 6 1 m 9 8528 Art A 03008 NOTE Illustration may vary slightly from unit Manual 0 2957 6 3 PARTS LISTS 6 05 Left Side Internal Component Replacement Parts Item Qty Description Ref Catalog 1 1 Fuse F1 for 208 230 Volt Power Supplies 9 8588 for 400 Volt and 415 Volt Power Supplies 9 8602 for 460 Volt Power Supplies 9 8583 for 600 Volt Power Supplies 9 8638 Main Input Contactor W1 2A for 208 230 Volt Power Supplies 9 8587
58. dnt Hie cv C tp av LU E Dr ieee EL Hk nea veu aiaa A 2 APPENDIX 3 LOGIC PC BOARD LAYOUT Nt A 3 APPENDIX 4 MAIN POWER PC BOARD LAYOUT Nt A 4 APPENDIX 5 MAIN PC BOARD WIRING LAYOUT 208 230 Volt Units A 6 APPENDIX 5B MAIN PC BOARD WIRING LAYOUT 400 Volt 415 Volt 460 Volt and 600 Volt Units pp 7 APPENDIX 6 LED POT BOARD 2 20 nnne nnns A 8 APPENDIX 7 INPUT DIODE PC BOARD LAYOUT iii A 9 APPENDIX 8 IGBT CIRCUIT PC BOARD A 10 APPENDIX 9 OUTPUT DIODE PC BOARD A 11 APPENDIX 10 OUTPUT BOARD WIRING A 12 APPENDIX 11 PILOT PC BOARD LAYOUT Ne A 13 APPENDIX 12 28VAC CIRCUIT DIAGRAM nennen nennen enne nnns A 14 APPENDIX 13 DATA TAG INFORMATION Ne A 15 APPENDIX 14 TORCH PIN OUT 16 APPENDIX 15 TORCH CONNECTION DIAGRAMS Ne A 17 APPENDIX 16A SYSTEM SCHEMATIC 208 230 Volt Units pp 18 APPENDIX 16B SYSTEM SCHEMATIC 400 Volt 415 Volt and 460 Volt Units pp A 20 APPENDIX 16C APPENDIX 16C SYSTEM SCHEMATIC 600 Volt Units A 22 APPENDIX 17 Publication History is A 24 Global Customer Service Contact Information Inside Rear Cover SECTION 1 GENERAL INFORMATION 1 01 Notes Cautions and Warnings Throughout this manu
59. e Connections 400V 415V 460V 600V Units Input Diode To Main PCB 208 230V Units dade E6 E14 E16 E15 E14 E16 For IGBTs a Apply a round thermal pad to the heatsink with a small piece of light duty tape The tape must cover no more than 1 8 3 mm of the edge of the thermal pad Use the screw hole inthe heatsink as a guide to position the board Round Output Diode Tape Thermal Pad or IGBT S y amp Washer Screw 3 Art A 03702 b Secure replacement board s with the screw removed previously Ensure that the washer is under the head of the screw 9 Torque screw s to 17 in lb 1 9 Nm NOTE Failure to torque properly will cause component damage 10 Connect wires per the chart CutMaster 81 IGBT Connections IGBT IGBTB F A To PCB IGBT Main PCB Connector Connector Connector Connector 11 Stand the unit upright reinstall the cover REPLACEMENT PROCEDURES 5 6 Follow the antistatic procedures in subsection 5 02 Remove cover per subsection 5 04 A Remove the Logic PC Board per subsection 5 06 C Disconnect all wire and cable connections to the Main PC Board Refer to the Main PC Board Wir ing Diagrams in the Appendix Pages if necessary Straighten the connections to the smaller PC Boards to be perpendicular to the Main PC Board Remove the two long Transformer screws secur ing the Transformer to the Center Chassis Remove the other
60. e CutMaster 81 Power Sup ply 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 02 Anti Static Handling Procedures A General Caution PC Boards can be irreparably damaged by im proper handling due to electrostatic discharge ESD Replacement PC Boards are shipped in a protective en closure to prevent damage from electrostatic discharge ESD during shipping A ground strap is included with each replacement board to prevent static damage during installation GS Read and understand these instructions and the instructions on the grounding wrist strap package before opening the equipment enclosure or remov ing the replacement PC board from its protective enclosure Disconnect primary power to the system before dis assembling the torch torch leads or power supply enclosure Where these instructions include specific torquing instructions failure to torque properly will cause component damage Do not operate the equipment or test equipment under power while wearing the grounding wrist strap Manual 0 2957 Procedure 1 Open the wrist strap and unwrap the first two folds of the band Wrap the adhesive side firmly around your wrist Unroll the rest of the band and peel the liner from the copper foil at the opposite end Attach the copper foil to a convenient and ex
61. e from the unit 4 Install the replacement Input Power Cable by re versing the above steps The Input Power Cable ground wire requires a ring terminal Rear Panel Replacement G Disconnect primary input power and the gas sup ply at the source and bleed down the system before performing this procedure 1 Remove the cover per subsection 5 04 A 2 Remove the primary input power cable per sec tion 5 07 C 3 Remove the Regulator Filter Assembly per sec tion 5 07 A 4 Remove two bolts at the bottom corners of the Rear Panel 5 Remove one nut on a stud on the inside of the Rear Panel at the rear edge of the center chassis 6 Replace the Rear Panel by reversing the above steps 7 If not already done attach the data tag s pro vided with the replacement Rear Panel Position these as on the original Rear Panel REPLACEMENT PROCEDURES 5 08 Right Side Internal Parts Replacement Refer to Section 6 07 Right Side Internal Component Parts List and overall detailed drawing A G Disconnect primary power from the source before opening or disassembling the power supply A Pressure Switch Solenoid Assembly Replacement The Pressure Switch and Solenoid Valve are one Assembly Disconnect primary input power and bleed down the sys tem 1 Remove the cover per subsection 5 04 A 2 Disconnect the following wires a Wires 10 and 11 from the Pressure Switch Assembly b Wires 8 and 9
62. e put back in the same place when installing the replacement module Manual 0 2957 5 5 Remove screw s securing PC Board s to the heat sink and remove board s from the Power Sup ply Use isopropyl alcohol and a clean rag to clean the heatsink or chassis area behind the component be ing replaced Clean the large flat surface on the back of the replacement component Do not scratch or abrade the surface The thermal pad s provided with the replace ment part is a thin metal pad Remove any loose protective paper coverings from the pad s NOTE Protective coverings must be removed from the thermal pads Installing thermal pads with pro tective coverings in place will cause equipment damage or failure 8 Install replacement components as follows For Input Diodes Slot Thermal Pad Art 03950 Input Diode Replacement a Apply the thermal pad to the flat surface of the diode Align the pad with the rectangu lar flat surface on the back of the device b Align the diode horizontally with its longer edges perpendicular to the power supply base c Secure the device and rectangular pad to the chassis with the replacement screws and wash ers Torque screw s to 35 in lb 3 95 Nm NOTE Failure to torque properly will cause component dam age REPLACEMENT PROCEDURES 10 Connect wires per the chart E Main Power PC Board Replacement CutMaster 81 Input Diod
63. e soudage R parez ou remplacez toute pi ce us e ou endommag e Prenez des soins particuliers lorsque la zone de tra vail est humide ou moite Montez et maintenez le mat riel conform ment au Code lectrique national des Etats Unis Voir la page 5 article 9 D branchez l alimentation lectrique avant tout tra vail d entretien ou de r paration Lisez et respectez toutes les consignes du Manuel de consignes A o ET EXPLOSION Les incendies et les explosions peuvent r sulter des scories chaudes des tincelles ou de l arc de plasma Le proc d l arc de plasma produit du m tal des tincelles des scories chaudes pouvant mettre le feu aux mati res com bustibles ou provoquer l explosion de fum es inflammables Soyez certain qu aucune mati re combustible ou in flammable se trouve sur le lieu de travail Prot gez toute telle mati re qu il est impossible de retirer de la zone de travail Procurez une bonne a ration de toutes les fum es inflammables ou explosives Necoupez pas et ne soudez pas les conteneurs ayant pu renfermer des mati res combustibles Pr voyez une veille d incendie lors de tout travail dans une zone pr sentant des dangers d incendie Le gas hydrog ne peut se former ou s accumuler sous les pi ces de travail en aluminium lorsqu elles sont coup es sous l eau ou sur une table d eau NE PAS couper les alliages en aluminium sous l eau ou sur une tab
64. emperature If resistance is not 10K 12 Faulty Main PC Board ohm 25 replace TS1 Measure for 12 vdc on Main PC Board from 4 to b Shut input power off Check Inductor Temp TP1 Switch TS2 Disconnect wire connector P32 from terminal J32 on PC Board Check a If voltage is not present replace the Main PC connector pins 1 and 2 for resistance If resis Board tance is greater than 12K ohms replace output on inductor L1 If temp switch is open replace D Fans do not run GAS and TEMP Main PC Board indicators ON DC indicator off E Nogas flow RUN RAPID AUTO RESTART SET switch in SET position AC indicator ON A TEMP 5 and DC indicators OFF ik xx A e rn E e 0 5 e c e sss e E 1 Airflow through unit is restricted D 9 ke a Provide adequate air flow 2 Exceeded Duty Cycle of Power Supply 1 Gas supply not connected to unit a Deactivate torch and wait for fan to cool unit Refer a Connect to gas supply to Specifications Section for proper duty Cycle for ibis unit 2 Gas supply not turned on 3 Faulty Fan s a Turn gas supply on Measure for 230 VAC on the Main PC Board 3 Gas pressure too low from J15 1 to J15 5 and from J15 2 to J15 6 a Adjust gas pressure per pressure setting label Ifvoltage atJ15 1 to J15 5 is correct replace lower on power supply Fan M1 4 Faulty RUN RAPID AUTO RESTART SET switch Ifvoltage
65. esent in thepower supply TEMP When lighted indicates the power supply is overheated 00 GAS When lighted indicates that adequate input air pressure for power supply operation is present e When lighted indicates that power supply output circuits are active NOTE Minimum pressure for power supply operation is lower than minimum pressure for torch operation 3 Dimensions and Weight 83 Ib 37 6 kg 17 3 in 439 mm 12 4 in 315 mm A 03572 3 03 Air Regulator Filter Assembly Specifications The following specifications apply to the Air Regulator Filter Assembly only 1 Operating Pressure 65 psi 4 5 bar 2 Maximum input air supply pressure 125 psi 8 6 bar Manual 0 2957 3 3 DESCRIPTION This Page Left Blank DESCRIPTION 3 4 Manual 0 2957 SECTION 4 TROUBLESHOOTING 4 01 Introduction This section provides service diagnostics for the CutMas ter 81 Power Supply allowing the Technician to isolate any faulty subassemblies Refer to Section 5 Repairs amp Replacement Procedures for parts replacement instruc tions 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 fac tory warranty NOTE The troubleshooting contained in this manual is for the Power Supply only Troubleshooting other parts of the system is covered in the manuals
66. faut communiquer aux op rateurs et au person nel TOUS les dangers possibles Afin d viter les blessures possibles lisez comprenez et suivez tous les avertissements toutes les pr cautions de s curit et toutes les consignes avant d utiliser le mat riel Composez le 603 298 5711 ou votre distributeur local si vous avez des questions NENNEN et GAZ sant 1 3 La fum e et les gaz produits par le proc d de jet de plasma peuvent pr senter des risques et des dangers de GENERAL INFORMATION Eloignez toute fum e et gaz de votre zone de respira tion Gardez votre t te hors de la plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les gaz Les sortes de gaz et de fum e provenant de l arc de plasma d pendent du genre de m tal utilis des rev tements se trouvant sur le m tal et des diff rents proc d s Vous devez prendre soin lorsque vous coupez ou soudez tout m tal pouvant contenir un ou plusieurs des l ments suivants antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre s l nium b ryllium mangan se vanadium Lisez toujours les fiches de donn es sur la s curit des mati res sigle am ricain MSDS celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS contiennent des renseignements quant la quantit et la nat
67. for those products 4 02 Periodic Inspection amp Cleaning Procedures A WARNING Disconnect primary power and bleed down the sys tem before disassembling the torch leads or power supply To clean the unit open the enclosure per procedure in section 5 05 A Cover Removal and use a vacuum cleaner to remove any accumulated dirt and dust The unit should also be wiped clean If necessary solvents for cleaning electrical apparatus may be used Refer to the Appendix for maintenance schedule and pro cedures Manual 0 2957 4 03 System Theory A Logic PC Board Functions The Logic PC Board controls the timing and sequenc ing of the system It monitors gas pressure and power supply internal temperatures and controls the gas flow The Logic Board also controls the safety latch circuit After the ON OFF switch is closed on the front panel the AC Indicator turns on 20 The GAS indicator is ON when there is sufficient gas pressure in the power supply to enable power sup ply operation NOTE Minimum gas pressure for power supply operation is lower than the minimum for torch operation When the unit is at idle the AC indicator J on the Front Panel should be ON When the torch is acti vated the gas begins to flow After a brief preflow the INV ON signal is given and the DC indicator the Front Panel turns ON Anopen circuit voltage of approximately 230 to 300 vdc depending on i
68. from the Solenoid Assembly 3 Push the clip on the front of the Heatsink Shroud to the left to release the Solenoid Assembly Dis lodge the Assembly from underneath the clip on the top of the Heatsink Shroud Push Clip to the left to release Solenoid Assembly Art A 03705 Shroud 4 Release the hose from the Adapter Fitting on the input side of the Solenoid Assembly Hold a wrench or similar tool against the locking ring on the Fitting then pull on the hose to release it REPLACEMENT PROCEDURES Release the hose from the Adapter Fitting on the output side of the Solenoid Assembly Install the replacement Pressure Switch Solenoid Assembly by reversing steps 2 5 Once installed the Solenoid Assembly should fit securely on the Heatsink Shroud It should not be moveable 7 Re install the power supply cover B Pilot PC Board Assembly Replacement Follow the antistatic procedures in subsection 5 02 5 8 1 6 Remove the power supply cover per subsection 5 04 A Label then disconnect the wiring connections to the Pilot PC Board Assembly a J28 Connector b Wire connectors to terminals E58 and E62 Remove the bolts securing the PC Board to the standoffs Slide the PC Board upward to release it from its bottom supports Install the replacement Pilot PC Board Assembly by reversing the above steps Reinstall the Power Supply cover Fan Replacement M1 M2 1 2 Remove the cover per sub
69. fully remove all wire connections to the Out put Diode Board s Remove screw s securing Output Diode PC Board s to the Heatsink and remove board s from the Power Supply Use isopropyl alcohol and a clean rag to clean the heatsink Do not scratch or abrade the heatsink Apply the thermal pad provided with the replace ment PCB to the heatsink Secure in place with small pieces of masking tape The tape must cover no more than 1 4 6 mm of the edge of the ther of the Power Supply mal pad 3 Ensure that the hole in the bottom flange of the Fan Assembly Panel engages the Round mounting stud Output Diode Tape Thermal Pad or IGBT c Replacenut on the bottom mounting stud Em 29 d Ensure that the Fan Panel s top flange is fully Washer against the top forward edge of the Heatsink Screw Shroud N e Press the front panel of the Power Supply oj dde against the Fan Panel and fasten in place with the bolt removed in Step 2 f Securethe nuton the stud at the bottom of the Fan Panel Re connect the wires to the Fan Assemblies Pass the Work Cable through the hole in the bot tom of the Fan Panel Ensure that the grommet is in place in the hole Connect the Work Cable to terminal E61 on the Power Output PC Board Secure the Work Cable Use isopropyl alcohol to clean the large flat sur face on the back of the component Secure replacement board as follows a Position the hardware at the bottom of a re
70. he Heatsink Shroud 7 Reinstall the Pilot Board Reconnect the wires to the Pilot Board Reconnect the torch receptacle ground wire to the center chassis 9 Replace the Pressure Switch Solenoid Assembly This assembly fits into a slot in the top horizontal surface of the Heatsink Shroud A notched pin holds the assembly in place 10 Connect the gas hose between the Regulator Fil ter Assembly and the Gas Pressure Switch Sole noid Assembly 11 Connect wiring to the Output Power PC Board Refer to the Appendix pages for wiring layout 12 Replace the Power Supply rear panel per subsec tion 5 07 D This concludes the replacement procedures REPLACEMENT PROCEDURES 5 12 Manual 0 2957 SECTION 6 PARTS LISTS 6 01 Introduction A Parts List Breakdown The parts lists provide a breakdown of all replaceable components The parts lists are arranged as follows Section 6 03 Major External Replacement Parts Section 6 04 Front Panel Replacement Parts Section 6 05 Left Side Internal Component Replacement Parts Section 6 06 Rear Panel Replacement Parts Section 6 07 Right Side Internal Component Replacement Parts Section 6 08 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 distributor Materials returned without proper authori zation will not be accepted 6 02 Or
71. he above steps Note that the output power PC Board includes a jumper wire between studs E58 and E57 Refer to Appendix 10 for output power PC Board wir ing details F Heatsink Shroud Assembly Removal The Heatsink Shroud Assembly must be disengaged for access to either the Main Transformer or the Output In ductor Follow these steps for access to either compo nent 1 10 12 Remove the Power Supply cover per subsection 5 04 A Release the tab on the vertical face of the Heat sink Shroud securing the Solenoid Pressure Switch Assembly in position Remove the gas hose from the Regulator Fitting on the back panel of the Power Supply by press ing on the locking ring on the elbow fitting while pulling on the hose Remove the Power Supply Back Panel per sub section 5 07 D Remove the grommets from the two holes on the right rear edge of the Heatsink Shroud Remove the Fan Assembly per subsection 5 08C Label and disconnect the wires connected to the Pilot PC Board Remove the hardware securing the Pilot PC Board in place Pull the PC Board off the center chassis Label and disconnect wires No 45 47 49 and 52 from the Power Output PC Board Disconnect the wires from the Output Inductor to terminal E43 on the Power Output PC Board Disconnect the torch receptacle ground wire con nected to the center chassis Remove nuts on two studs at the top corners of the Heatsink Shroud and nuts on two st
72. he switch through the Front Panel Install the replacement Switch by reversing the above steps D POT LED PC Board Replacement Follow the antistatic procedures provided in subsection Remove the cover per subsection 5 04 A Remove Current Knob per Subsection 5 05 A Disconnect wire harness Connector from POT LED PC Board Remove PC Board from standoffs Install the replacement POT LED PC Board by reversing the above steps Work Cable Replacement 1 2 Remove the cover per subsection 5 04 A Disconnect the Work Cable from the E61 WORK terminal on the Power Output PC Board located on the right side of the unit Squeeze the top and bottom of the Work Cable Strain Relief and remove from the Front Panel Remove Work Cable from the unit Install the replacement Work Cable a Ensure that the replacement Work Cable passes through the grommet in the Fan Assem bly Panel b Secure the Cable to the Work terminal on the Power Output PC Board and securing the strain relief REPLACEMENT PROCEDURES 5 06 Left Side Internal Parts Replacement Connections to Main PCB Refer to subsection 6 05 Left Side Internal Component Replacement Parts and overall detailed drawing A G Disconnect primary power from the source before opening or disassembling the power supply A Fuse Replacement 1 Remove the cover per subsection 5 04 A Main Contactor 2 Locate the Fuse near the top edge of
73. hire 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 Euro pean Council Directive 89 336 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 CENELEC EN50199 EMC ProductStandard for Arc Welding Equipment ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting equipment and associ ated accessories For environments with increased hazard of electrical shock Power Supplies bearing the mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips if equipped with properly installed standoff guides Ex
74. ic PC Board and the extender board from the Main Power PC Board Detach the ex tender board from the Logic Board Install the replacement Logic PC Board by revers ing the above steps The pins on the right edge of the Logic PC Board must fully engage the sockets on the edge of the extender board The extender board must fully engage sockets on the Main Power PC Board D IGBT Circuit Board or Input Diode Board Replacement Follow the antistatic procedures in subsection 5 02 The Power Supply includes two IGBT Circuit PC Boards NOTE Follow the electrostatic discharge instructions pro vided with the replacement component to prevent damage to the component Thermal pads heatsinks and the large flat surface on the back of diodes and IGBTs must be kept clean Diodes and IGBTS must not be bent or allowed to pick up any foreign material A very clean instal lation between the module and the heatsink or chas sis is essential for proper operation 1 2 3 Remove cover per subsection 5 04 A Turn the Power Supply onto its side Locate the IGBT Circuit PC Boards or Input Di ode mounted within the Main Power PC Board Refer to Appendix pages for location and posi tion For IGBTs remove the small jumpers between the IGBT and the Main PC Board Transfer these jumpers to the replacement IGBT Label then re move all other wire connections to the Board s being replaced Note the routing of wires En sure that the wires ar
75. imary power at the source before dis assembling the power supply torch or torch leads Testing of diode modules requires a digital volt ohm meter 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 1 2 Locate the diode module to be tested Remove cables from mounting studs on diodes to iso late the module Set digital volt ohmmeter to diode test scale 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 Manual 0 2957 5 Connect the volt ohmmeter positive lead to the an ode of the diode and the negative lead to the cathode of the diode for forward bias testing re fer to following figure A properly functioning di ode will conduct in the forward bias direction and indicate between 0 3 to 0 9 volts Art A 00307 0 75 Forward Bias Diode Conducting Db Diode Test Symbol VR COM A Anode Sy Cathode Testing Diode Forward Bias 6 Reversethe meter leads across the diode for reverse bias testing refer to following figure A properly functioning diode will block in the reverse bias di rection and depending on the meter function will indicate an open or OL
76. in PCB a Test per Subsection 4 10 F repair as needed a Check wiring connection Refer to the System Schematic in the Appendix Connections AC L GAS and DC indicators ON should be L e Wire 58 to Pilot Board terminal E58 TEMP indicator off E Noarcorintermittent arc in torch Gas flows Wire 62 to Pilot Board terminal E62 If wires 58 and 62 are not connected to the proper terminals replace the Pilot Board e f 7 Faulty Main PC Board a Check for approximately 12 vdc at TP4 to TP1 If less than 2 vdc replace the Main PC Board Art A 03992 i 8 Faulty Logic Board or Faulty Pilot Board Pilot Board and retry piloting If torch pilots S with jumper installed replace Pilot Board If torch does not pilot replace Logic Board a Install a jumper between wires 58 and 62 on 1 Gaspressure set incorrectly too high a Reset gas pressure per pressure setting label on power supply Manual 0 2957 4 13 TROUBLESHOOTING 4 09 Main Arc Problems Locate your symptom below A Main cutting arc will not start 1 Workcablenot connected a Connect work cable 2 Holding too high of a standoff a Referto recommended standoff heights Adjust as needed 3 Workpiece is painted or rusty a Clean workpiece 4 Faulty Main PC Board or Logic Board a Measure for 0 vdc at TP2 to TP1 on the Logic Board when attempting to transfer Refer to Logic Boar
77. ing rating Pag EU ioci DC Voltage 98V Duty Cycle 400V and 415V Units Current DC Voltage DE 600V Units NOTE The duty cycle will be reduced if the primary input power AC Input Power NOTE IEC Rating is determined as specified by the International Electro Technical Commission These specifications include calculating an output voltage based upon power supply rated current facilitate comparison between power supplies all manufacturers use this output voltage to determine duty cycle TDC Rating is determined using an output voltage representative of actual output voltage during cutting with a TDC torch This voltage may be more or less than IEC voltage depending upon choice of torch consumables and actual cutting operation Manual 0 2957 3 1 DESCRIPTION Handle and Leads Wrap Control Panel Art A 03578 Work Cable and Clamp Gas Pressure Regulator Filter Assembly Gas Inlet Port Ports for Optional Automation Interface Cable E Art A 03738 DESCRIPTION 3 2 Manual 0 2957 1 Front Panel Controls and Features Main Power ON OFF Switch e RUN RAPIDAUTORESTART SET Switch r ET numm Output Current Control A Sets output current for drag cutting up to 40 Amps for drag cutting with the torch tip in contact with the workpiece or for standoff cutting up to 60 amps 2 Front Panel Indicators AC When lighted indicates AC input power is pr
78. le d eau moins que le gas hydrog ne peut s chapper ou se dissiper Le gas hydrog ne accumul explosera si enflamm m RAYONS D ARC DE PLASMA Les rayons provenant de l arc de plasma peuvent blesser vos yeux et br ler votre peau Le proc d l arc de plasma produit une lumi re infra rouge et des rayons Manual 0 2957 ultra violets tr s forts Ces rayons d arc nuiront vos yeux et br leront votre peau si vous ne vous prot gez pas correctement Pourprot ger vos yeux portez toujours un casque ou un cran de soudeur Portez toujours des lunettes de s curit munies de parois lat rales ou des lunettes de protection ou une autre sorte de protection oculaire Portez des gants de soudeur et un v tement protecteur appropri pour prot ger votre peau contre les tincelles et les rayons de l arc Maintenez votre casque et vos lunettes de protection en bon tat Remplacez toute lentille sale ou comportant fissure ou rognure Prot gez les autres personnes se trouvant sur la zone de travail contre les rayons del arc en fournissant des cabines ou des crans de protection Utilisez la nuance de lentille qui est sugg r e dans le recommendation qui suivent ANSI ASC 249 1 Nuance Minimum Nuance Sugger e Courant Arc Protective Num ro Num ro Moins de 300 8 9 300 400 9 12 400 800 10 14 Ces valeurs s appliquent ou l arc actuel est observ clairement L experience a d montrer que les filt
79. lock it into position c Checkfor proper installation the transformer should remain securely in place Pass wires 27 and 32 through the hole in the cen ter of the main chassis Connect wire 27 to ter minal E27 and wire 32 to terminal E32 on the Main Power PC Board Replace the Heatsink Shroud Assembly per sub section I H Output Inductor Assembly Removal and Replacement 1 2 Disengage the Heatsink Shroud per paragraph H Disconnect the wires to the thermal switch on the Output Inductor Remove hex nuts at the left forward and right rear corners of the Inductor base Remove the Inductor as follows a Note the position of the wires leading from the Inductor Manual 0 2957 b Liftoutthe Inductor through the opening at the rear of the Power Supply It may be necessary to lift the Main Transformer slightly to create room for the Inductor to pass through the rear opening 5 Install the replacement Inductor a Putthereplacement Inductor in place with the wires oriented the same way as the original Inductor b Secure the Inductor in place with hex nuts at opposite corners of the Inductor base 6 Reconnect the wires to the thermal switch on the Output Inductor 7 Replace the Heatsink Shroud per paragraph I l Heatsink Shroud Assembly Replacement 1 Pass transformer wires 45 and 49 through the upper hole in the right rear edge of the Heat sink Shroud Pass transformer wires 47 and 52 thro
80. m Supply Current Input Power Symbol ES U1 id Tmax 1gl 1er Maximum Effective Supply Current Input Power Specifications Phase AC or DC Hertz Rating Manufacturer s Electrical Schematic File Number Rated Supply Voltage Note 2 Degree of Protection NOTES 1 2 Manual 0 2957 Symbol shown indicates single or three phase AC input static frequency converter transformer rectifier DC output Indicates input voltages for this power supply Most power supplies carry a label at the input power cord showing input voltage requirements for the power supply as built Top row Duty cycle values IEC duty cycle value is calculated as specified by the International ElectroTechnical Commission TDC duty cycle value is determined under the power supply manufacturer s test procedures Second row Rated cutting current values Third row Conventional load voltage values Sections of the Data Tag may be applied to separate areas of the power supply A 15 and Revision Level Standard Symbols AC zc e Phase Art A 03288 APPENDIX APPENDIX 14 TORCH PIN OUT DIAGRAMS A Hand Torch Pin Out Diagrams Front View Front View aus iN ZO 4 Green 8 Open 8 Ground M 4 Bram 7 Open 7 Open li 8 6 Open W 29 7 Switch n NEBST 7 D 7 3 White Capi
81. move shield cup in stall missing parts TROUBLESHOOTING 3 Torch starter cartridge is stuck a Turnoff power supply Remove shield cup tip and starter cartridge Check lower end fitting on starter cartridge for free movement Replace cartridge if lower end fitting does not move freely Start Cartridge Lower End Fitting 4 Wornor faulty torch parts Art A 03621 a Inspecttorch consumable parts Replace if nec essary C Torch will not pilot AC _ TEMP 3 and GAS indicators ON DC indicator off A 2 e 0 B Art A 03989 rm n 1 Air flow blocked a Check for blocked air flow around the unit and correct condition 2 Unit is overheated a Letunitcool down for atleast 5 minutes Make sure the unit has notbeen operated beyond Duty Cyclelimit Referto duty cycle data in Specifi cations Section 3 Input Line Voltage is low a Check and connect to proper input power line TROUBLESHOOTING 4 12 4 Faulty Temperature Sensor Switch Turn off input power for the following tests a Check IGBT Heatsink Temp Sensor 151 Dis connect wire connector P29 from terminal J29 on Main PC Board Check connector pins 1 and 2for 10k ohm 2576 atambient temperature If resistance is not 10K ohm 25 replace TS1 b Check Inductor Temp Switch TS2 Disconnect wire connector P32 from terminal J32 on Main PC Board
82. nput power is produced when the switching of the IGBTs in the Main PC Board is turned ON by an INV ON signal from the Logic PC Board A circuit on the Logic PC Board monitors the output volt age When theoutput voltage drops below 60 vdc indi cating a problem exists the Logic PC Board sends a sig nal which tums OFF the INV ON Enable signal This happens in less than 50 milliseconds When the torch is activated gas will flow for approxi mately two seconds before DC is established indi cated on the front panel Then the gas shuts off briefly The gas flow then starts again and the torch starts a pilot arc When the torch is close to the workpiece the cutting arc transfers to the work The resulting current is sensed by the Current Sense circuit resulting in the demand level changing from pilot current to the main current control setting and then the main cutting arc starts If the torch is removed from the workpiece while the torch switch is still pressed the main arc extinguishes and the pilot arc automatically restarts CutMaster 81 Logic Board Indicators 033 Switch ON Drag Circuit ON 4 1 TROUBLESHOOTING 4 04 Common Operating Problems Aes Disconnect primary power at the source before dis assembling the power supply torch or torch leads Frequently review the Important Safety Precau tions in Section 1 Be sure the operator is equipped with proper gloves clothing and eye and ear pro
83. nt for power supply operation NOTE Minimum gas pressure for power supply operation is lower than the minimum for torch operation DC indicator is OFF Gasflows Fans operate Set the Power Supply RUN RAPID AUTO RESTART SET switch to the RUN up position and note the following Gas flow stops This completes the Main Input and Internal Power Tests If the above are all correct then proceed to paragraph D If not note the symptom and proceed to Subsection 4 07 Main Input and Internal Power Problems 4 4 Manual 0 2957 D Pilot Arc Test 1 Activate the torch press torch switch on the handle send START signal from CNC Control or press the torch switch on the Remote Pendant to establish a pilot arc and note the following e Gas flows Preflow delay approximately two seconds then DC indicator turns ON Pilot arc is established This completes the Pilot Arc Test If the above are all cor rect then proceed to paragraph E If the unit does not function properly then note the symptom and proceed to Subsection 4 08 Pilot Arc Problems E Main Arc Test Make sure the work cable is firmly connected to the work piece Activate the torch press torch switch on the handle send START signal from CNC Control or press the torch switch on the Remote Pendant to establish a pilot arc Bring the torch to within 1 8 3 8 3 10 mm of the work piece to establish the main cutting arc and no
84. oad Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Email sales thermalarc com Thermadyne Canada 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Thermadyne Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park JIn Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Cigweld Australia T1 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7510 Thermadyne Italy OCIM S r L Via Benaco 3 20098 5 Giuliano Milan Italy Tel 39 02 98 80320 Fax 39 02 98 281773 Thermadyne International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 16062 Swingley Ridge Road IHERMAL DYNAMICS SLE MO 63017 By THERMADYNE Telephone 636 728 3000 Email TDCSales Thermadyne com www thermadyne com
85. oints are essential to properly support the application and operation of this equipment A Application The equipment should satisfy the customer s require ments 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 selec tion 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 mali cious damage D Repair Restrictions The electronics consists of Printed Circuit Board PCB 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 2 03 Service Responsibilities The service technician should be familiar with the equip ment and its capabilities and should be prepared to rec ommend arrangements of components which will pro vide the most efficient layout utilizing the equipment to its best possible advan
86. ors OFF e e Art A 03988 ae 4 M e 1 Gaspressure is below power supply minimum require ment a Adjust gas pressure per pressure setting label on power supply 2 Upper O ring on torch head is in wrong position a Removeshield cup from torch check position of upper O ring Correct if necessary Upper Groove with Vent Holes Must Remain Open Came Upper O Ring in Correct Groove Threads Lower O Ring Art 03725 Manual 0 2957 4 11 B 3 Faulty IGBT s a Measure between the following points on the IGBTs e IGBT E4to E10 E10 to E20 B E23 to E27 E27 to E30 Voltage should be approximately 20 vdc before the start signal is active If voltage measures greater than 100 vdc when the start signal is active replace the respective IGBT s Torch will not pilot RUN RAPID AUTO RE START SET switch in RUN or RAPID AUTO RESTART AC and GAS indicators ON Temp and DC indicators OFF 0 1 Gas pressure is below torch minimum requirement NOTE Minimum pressure for power supply opera tion is lower than minimum required for torch opera tion Art A 03990 gt a Adjust gas pressure per pressure setting label on power supply 2 Torch tip starter cartridge or electrode missing a Turn off power supply Re
87. ove the nut and washer from the ground stud read the procedure for the part to be replaced then pro on the inside of the cover ith the di bly 4 Install thereplacement cover by reversing the above 5 04 Major External Parts steps Replacement B Tube Handle Replacement Refer to Section 6 03 for Major External Replacement Parts ML and overall detailed drawing 2 Remove the Fan Assembly Panel per section 5 08 C WARNING 3 Remove the four bolts and star washers securing the frame to the base of the unit 4 Movetheinput power cable torch leads and work cable inside the handle Lift the base of the unit away from the Tube Handle Leave the rear panel fastened to the base assembly Disconnect primary power from the source before opening or disassembling the power supply A Cover Removal and Replacement 5 With a rubber mallet separate the two handle 1 Remove the upper screws securing the cover to ends as shown below the unit Loosen the lower screws securing the cover to the base Install the replacement Tube Handle by revers ing steps 1 4 7 Replace the Fan Assembly Panel per section 5 08 C Upper Screws 8 Re install the Power Supply cover Screws Lower ss PA Ground wire Art A 02847 Art A 03792 2 Carefully lift the cover up and away from the unit for access to the ground wire connection on the inside of the cover REPLACEMENT PROCEDUR
88. p lt Switch s eC 2 Orange PASE 6 NL x PIP TTL 5 Open 5 Open 2 xum Pilot NSD SS 1 Black PI Pilot B Mechanized Machine Torch Pin Out Diagrams ATC Female Receptacle UNSHIELDED MACHINE TORCH aid Negative Plasma ATC Male Connector Front View Negative Plasma 7 8 Fan MG Fay 3 Switch 2 7 2 PIP xdi Of NS 2 6 S 5 White 5 Open SS 1 PIP ot Used Pilot zo Manual 0 2957 APPENDIX APPENDIX 15 TORCH CONNECTION DIAGRAMS A Hand Torch Connection Diagram Torch SL60 SL100 Hand Torch Leads Torch Leads with ATC Connector Power Supply with ATC Receptacle Male ATC Leads ATC Female Connector Receptacle Power mM Head Leads PIP OA Black o a hl a Orange Switch To Power Supply Circuitry Torch Green To Power Supply Circuitry z OO c O O1 N O Q NN Negative Plasma Negative Plasma Pilot Pilot Art A 03797 B Mechanized Machine Torch Connection Diagram Torch Unshielded Mechanized SL100 Machine Torch Leads Leads with ATC Connector and E Remote Pendant Connector To Remote Control Power Supply with ATC Female Receptacle Male RAR ATC Female Pendant R
89. p your head out of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases 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 met als which may contain one or more of the follow ing Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese 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 in formation regarding the kind and amount of fumes and gases that may be dangerous to your health 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 Use special equipment such as water or down draft cutting tables to capture fumes and gases Do not use the plasma torch in an area where com bustible 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 This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth de fects and in some cases cancer California Health amp Safety Code Sec 25249 5 et seq
90. posed electrical ground Connect the equipment primary cable ground to the same electrical ground as the wrist strap Open the equipment enclosure and remove the failed PC board Carefully open the ESD protective bag and re move the replacement PC Board Install the replacement PC Board in the equipment and make all necessary connections Place the failed PC Board in the ESD protective bag and seal for return shipping Replace the power supply cover 1 e Remove the grounding wrist strap from your wrist and from the electrical ground connection before reconnecting primary power to the equip ment 5 03 Parts Replacement General Information The parts replacement procedures described in this manual except for filter replacement require that the Power Supply be disassembled The part to be replaced will determine to what extent the Power Supply must be disassembled Before removing any connection mark each wire with the connection designation When reassembling make 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 re assembling the unit Each subsection is referenced to Section 6 for parts lists and overall detailed drawings A WARNING Disconnect primary power from the source before opening or disassembling the power supply 5 1 REPLACEMENT PROCEDURES Before disassembling any part of the Power Supply first 3 Rem
91. res moins fonc s peuvent tre utilis s quand l arc est cach par moiceau de travail Le bruit peut provoquer une perte permanente l ouie Les proc d s de soudage l arc de plasma peuvent provoquer des niveaux sonores sup rieurs aux limites normalement acceptables Vous d 4ez vous prot ger les oreilles contre les bruits forts afin d viter une perte permanente de l ouie Pour prot ger votre ou e contre les bruits forts portez des tampons protecteurs et ou des protections auriculaires Prot gez galement les autres personnes se trouvant sur le lieu de travail Il faut mesurer les niveaux sonores afin d assurer que les d cibels le bruit ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 Manual 0 2957 1 06 Documents De Reference Consultez les normes suivantes ou les r visions les plus r centes ayant t faites celles ci pour de plus amples renseignements 1 OSHA NORMES DE S CURIT DU TRAVAIL ET DE PROTECTION DE LA SANT 29CFR 1910 disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 2 Norme ANSI 749 1 LA S CURIT DES OP RATIONS DE COUPE ET DE SOUDAGE disponible aupr s de la Soci t Am ricaine de Soudage American Welding Society 550 N W LeJeune Rd Miami FL 33126 3 NIOSH LA S CURIT ET LA SANT LORS DES OP RATIONS
92. s __ I D p ATC RECEIVER MALE CONNECTOR E64 E64 E35 E62 CSR T E49 E45 E35 3 E61 E3 E1 E62 E43 E64 f Q u TIP PILOT CSR H CURRENT SENSE EN 2 JUMPER E58 E36 E57 E58 won E C1 MODE SW RAR OFF OUTPUT DIODE OUTPUT DIODE 52 AssEMBLY _ AssEMBLY _ 51 19 1757 19 1757 340 p E DC 2 2 E50A E50B 313 46 5 5 en D E53A ISENSE 8 8 18 ES4A 5 E54B PILOT BOARD CHASSIS GND ASSY 19 2157 E63 THRU SCREW TERMINAL Revisions Date PCB No Eco 8028 Rs owso JHERMAL DYNAMICS An sey No F 8016 RWH 01 27 06 WEST LEBANON NH 03784 Scale Supersedes DC COMMON DC COMMON THERMADYNE Company 82 Information Proprietary to THERMAL DYNAMICS CORPORATION Im POWER OUTPUT BOARD ASSY 19X1914 a Tor L References NOTE Uniass Otherwise Specified Resistors are in Ohms 14W 5 D Lija Capacitors are in Mirofarade UF Jee Shoat tot mE SCHEMATIC Size DWG No a Quina Tr T CM81 101 400 415 460V SYSTEM 42X1135 6 7 8 9 10 Art A 07152 Manual 0 2957 A 21 APPENDIX APPENDIX 16C APPENDIX 16C SYSTEM SCHEMATIC 600 Volt Units
93. se Return DC Com DC Com Not Used ISense Not Used Not Used Tip Volts Ground 12 vdc APPENDIX APPENDIX 5A MAIN PC BOARD WIRING LAYOUT 208 230 Volt Units To Press Switch Solenoid Contactor To Inductor Temp Sensor To Power Output Board LT1 To Heat Sink Temp Sensor Test Connector To On Off and Run Rapid Restart Set Switches To Main Input Contactor To Torch Connector To Chassis Ground To Fans Auto Interface eA Board J1 5 SX Auto Interface Board J1 6 To POT LED PCB or to Optional Remote Current Control Secondary e Transformer To Logic Board via Connector To Transformer J 9909999999 0990909090990999999099998 leri tans w Lo MAIN PCB ASSEMBLY 19 1929 4607 1
94. section 5 04 A Label then carefully remove the wiring connec tors from the terminals on the Fans Disconnect the Work Cable from terminal E61 on the Power Output Board Remove one bolt from the Front Panel of the Power Supply near the Control Panel Pull the Front Panel slightly away from the Power Sup ply Remove one nut from a stud at the bottom of the Fan Assembly Panel Lift the Fan Assembly Panel and pull it out of the Power Supply Manual 0 2957 7 Remove two bolts per Fan Set the Fan s aside D Output Diode PC Board Replacement 8 Install the replacement Fan Assembly as follows Follow the antistatic procedures in subsection 5 02 a Fasten Fan s in position with the wiring con 1 Remove cover per subsection 5 04 A nectors at the bottom of the Fan s 22 2 Locate the Output Diode located within the NOTE Only two screws are needed to attach the Fan to the Fan Panel They can be installed in any two holes provided they are opposite each other For grounding purposes one of those screws must be installed with a star washer 10 11 b Place the Fan Assembly Panel in position in the Power Supply 1 The inner edge of the Panel has tabs that engage slots in the center chassis Ensure that these tabs fully engage in the chassis 2 Press the Panel downward Press the bot tom flange fully against the bottom panel Output Power PC Board on the right side of the power supply Care
95. sub assembly must be returned for repair NOTE Follow all instructions as listed and complete each in the order presented Manual 0 2957 The troubleshooting guide has subsections as follows Section 4 06 Circuit Fault Isolation Section 4 07 Main Input and Internal Power Prob lems Section 4 08 Pilot Arc Problems Section 4 09 Main Arc Problems Section 4 10 Test Procedures Subsection 4 10 includes specific test procedures and in dicator status identification tables The subsection is ref erenced by the troubleshooting guide for the specific test to be performed The Power Supply is available for sev eral input voltages The technician must select the proper test points and measurements for the Power Supply being serviced B 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 iso late problem to possible circuit s per Subsection 4 06 Circuit Fault Isolation 2 Determine symptom and isolate to defective assem bly using the following format X Symptom Bold Type Any Special Instructions Text Type 1 Cause Italic Type a Text Type Locate your symptom in the appropriate Subsection Check the causes easiest listed first for the symptom Check the remedies listed
96. t EI gt 5 E10 CURRENT CONTROL LED PCB 19X1604 MAIN TRANSFORMER CURRENT SENSE P29 IGBT H HEATSINK 3 H TEMP E52 E47 INDUCTOR G J33 P33 ae TEMP OUT SENSE m DC COM x TIP SENSE 12006 74 1 SENSE 75 VOLTS 77 5 CONNECTION 5 CONFIGURATION Z J34 CONTACTOR ON 34 STANDARD 78 79 roeie c ASSY 19X1913 CM101 ASSY 19X2285 CM101 i AVDE ASSY 19X1932 CM81 DC COM ASSY 19X2284 CM81 DC COM WT ON TIP SENSE RUN SET Z PRESS GOOD INV o D13 EME 2 GASON DRAG ON D25 DE GK x SWON 14 TORCH TORCH SW RTN F 777 Por HG i CONNECTOR J23 ires ATC RECEIVER OUR N On CO N Te p p so l PIP RTN PIP D 280 ou 8 wN 80 87 EN BON 20 NOR ND Onkol 0 1 2 TORCH SW RTN SOLENOID ON 8 ANON co RON POTLOW 28VAC A GATE DRIVE B RTN GND 2 EST GATE DRIVEB 28VAC B 3 CONN DRIVE SOL1 FACTORY INSTALLED OPTIONAL A B
97. t of the defective product 3 Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics 4 Payment of credit up to the purchase price less reasonable depreciation based on actual use These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon NH or an authorized Thermadyne service station Product returned for service is at the owner s expense and no reimbursement of travel or transportation is authorized LIMITATION OF LIABILITY Thermal Dynamics Corporation 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 customer of distributors hereinafter Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics 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 the goods covered by or furnished by Thermal Dynamics 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 liability is based This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermal Dynamics product This warranty is invalid if
98. tacl Leads Connector Connector oN _____ Power Torch Supply Head Leads l PIP Oe Black Switch O Orange pe White Green Negative Plasma Lead Negative Plasma Pilot Lead To Power Supply Circuitry To Power Supply Circuitry O Pilot Art A 03798 Manual 0 2957 17 APPENDIX APPENDIX 16A SYSTEM SCHEMATIC 208 230 Volt Units
99. tage Maintenance work should be accomplished in a timely manner If problems are encountered or the equip ment does not function as specified contact the Tech nical Services Department at West Lebanon NH for assistance 1 603 298 5711 2 1 INTRODUCTION This Page Left Blank INTRODUCTION 2 2 Manual 0 2957 SECTION 3 DESCRIPTION 3 01 Scope The purpose of this section is 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 oper ating personnel The power supply includes all control circuitry electrical and air inputs and outputs pilot circuitry work cable with clamp and input power cable 3 02 Power Supply Specifications CutMaster 81 Power Supply Specifications 208 230 187 253 Single Phase 50 60 Hz 400 VAC 360 440 VAC Three Phase 50 60 Hz 415 VAC 370 460 VAC CE Three Phase 50 Hz 460 VAC 414 506 VAC Single Phase 60 Hz 460 VAC 414 506 VAC Three Phase 60 Hz 600 VAC 517 632 VAC Three Phase 60 hz Input Power Cable Cable for 208 230 VAC unit includes plug Output Current 20 60 Amps Continuously Adjustable Power Supply Gas Filtering Ability Particulates to 20 Microns CutMaster 81 Power Supply Duty Cycle Ambient Temperature 40 C 104 F eee Fotos TDC Rating IEC TDC IEC TDC IEC P rating Rang rating at
100. tch Gas should flow then stop after 2 seconds Front panel DC indicator should turn on Measure open circuit voltage between E61 to E43 at the Output Power PC Board Voltage should be greater than 200 V If voltage is less than 10 V refer to the diode test measurements in Section 4 10 C 2 Gate Drive amp Sensing 1 Shut off input power Replace the torch tip and electrode Remove thejumper betweenthe work lead and terminal E35 or E62 on the Output Power PC Board Install ajumper between and TP7 on the Logic Board Refer to Logic Board layout When the unit is turned on the DC light should remain ON Activate the torch After two seconds INV ON Indi cator D13 on the Logic PCB should come on and remain on indicator does not remain on replace Logic PCB e ON indicator remains on then check for at least 2 vdc between TP 1 to TP 11 and be tween 1 to TP 10 on the Logic PCB Refer to Logic Board Layout Ifnovoltage replace Logic PC Board If voltage is correct measure for at least 2 vdc between points as in the following chart IGBT A IGBT B JB Ifvoltage is 0 replace Main This completes the test procedures 4 19 TROUBLESHOOTING This Page Left Blank TROUBLESHOOTING 4 20 Manual 0 2957 SECTION 5 REPLACEMENT PROCEDURES 5 01 Scope This section describes parts replacement procedures which may be performed on th
101. te pendant control switch must also be closed Manual 0 2957 I 4 9 Gas cycles and off when power is turned on AC indicator flashes TEMP indicator off GAS indicator 25 D gt 1 Torch shield is loose a Tightenshield cup by hand Do notovertighten 2 Torch tip electrode or starter cartridge missing a Turn off power supply Remove shield cup in stall missing parts 3 Torch starter cartridge is stuck a Turn off power supply Bleed down the system Remove shield cup tip and starter cartridge Check starter cartridge lower end fitting for free movement Replace cartridge if lower end fit ting does not move freely Start Cartridge Lower End Fitting 0 4 Shorted power supply torch receptacle Art A 03621 a Turn Power Supply OFF Bleed down the system Disconnect the torch from the power supply Check the torch receptacle for continuity between the pilot connection and the negative plasma connection Refer to Appendix pages There should be no continuity 5 Shorted output power PC Board a Turn Power Supply OFF Bleed down the system Referto Appendix pages Output Board Wiring Dia gram Checkoutputpower PC Board for continuity betweenterminals E35 and E64 If continuity isfound replace Output Power PC Board TROUBLESHOOTING J23 J24 434 432 429 433
102. te the fol lowing Maincutting arc transfers to workpiece 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 If the torch does not function as noted then note the symp tom and proceed to Subsection 4 09 Main Arc Problems 4 07 Main Input and Internal Power Problems A Opening Power Supply Enclosure The cover of the Power Supply must be removed for ac cess to input power connections and test points Disconnect primary power at the source before as sembling or disassembling the Power Supply torch parts or torch and leads assemblies 1 Remove the upper screws securing the cover to the main assembly 2 Loosen but do not remove the lower screws NOTE There is a ground wire attached from the cover to the main body of the unit Manual 0 2957 3 Carefully lift the cover off the unit and remove thenut securing the ground wire to the side panel 4 Re install the cover by reversing the above steps Upper screws Screws Ground wire Art A 03792 Cover Removal Locate your symptom below A Main power line fuses blow as soon as main disconnect is closed 1 Input power cable installed incorrectly or defective power cord a Check that the input power cable is not defec tive or installed incorrectly Section 4 10 D il lustrates wiring connections 2 Maininp
103. tensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac turing 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 2957 1 7 GENERAL INFORMATION 1 08 Statement of Warranty LIMITED WARRANTY Subject to the terms and conditions established below Thermal Dynamics Corporation warrants to the original retail purchaser that new Thermal Dynamics CUTMASTER 1Series plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship Should any failure to conform to this warranty appear within the applicable period stated below Thermal Dynamics Corporation shall upon notification thereof and substantiation that the product has been stored operated and maintained in accordance with Thermal Dynamics specifications instructions recommendations and recognized industry prac
104. the Main Power PC Board and remove the Fuse from the fuse holder Art A 03194 3 Install replacement fuse 400 Volt 415 Volt 460 Volt and 600 Volt Input 4 Reinstall the power supply cover Contactor 3 phase input power connections shown B Main Input Contactor Replacement 1 Remove the cover per subsection 5 04 A 2 Label all wires connected to the Input Contactor 3 Disconnect wires to the Input Contactor from the input cable 4 Disconnect all other wires connected to the Input Contactor 5 Remove the two nuts and washers securing the Input Contactor to the base of the power supply 6 Position the replacement Input Contactor with the row of connectors labeled L toward the rear of the Power Supply Fasten in place with the hard ware removed previously 7 Complete the wiring connections as shown NOTE It is important that wires are installed correctly as shown to prevent damage to the unit Art 03212 8 Reinstall the power supply cover 208 230 Volt Input Contactor REPLACEMENT PROCEDURES 5 4 Manual 0 2957 C Logic PC Board Replacement Follow the antistatic procedures in Subsection 5 02 The Logic PC Board connects to the Main PC Board through an extender board perpendicular to both boards 1 2 Remove the cover per subsection 5 04 A Refer to Section 6 05 Left Side Internal Replace ment Parts Remove the bolts in each corner of the Logic PC Board Detach the Log
105. the Thermal Dynamics product is sold by non authorized persons Effective May 23 2005 GENERAL INFORMATION 1 8 Manual 0 2957 SECTION 2 INTRODUCTION 2 01 Scope Of Manual This manual provides service instructions for Thermal Dynamics CutMaster 81 Plasma Cutting Power Sup ply Information in this manual is particularly applicable to the troubleshooting and repair of this power supply and is intended for use by properly trained service tech nicians familiar with this equipment For setup of this equipment individual operating proce dures and basic troubleshooting refer to Operating Manual 0 2956 Read both the operating manual and the service manual thoroughly A complete understanding of the capabili ties and functions of this equipment will assure obtain ing the performance for which it was designed The CutMaster 81 Power Supply is available for the following input voltages 208 230 Volt Single Phase 400 Volt Three Phase 415 Volt Three Phase 460 Volt Three Phase 600 Volt Three Phase The 460 Volt Three Phase unit may be converted for Single Phase input power with a change of input power cord Manual 0 2957 This Service Manual covers all types Particular attention is required in the Trouble Shooting Section Section 4 to ensure that the technician selects the proper test points and measurements for the Power Supply being serviced 2 02 General Service Philosophy Several key p
106. tice correct such defects by suitable repair or replacement This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose Thermal Dynamics will repair or replace at its discretion any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below Thermal Dynamics Corporation must be notified within 30 days of any failure at which time Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor LIMITED WARRANTY PERIOD Power Supply Components Torch and Leads Product Parts and Labor Parts and Labor 51 CUTMASTER 81 CUTMASTERT 101 This warranty does not apply to T Consumable Parts such as tips electrodes shield cups o rings starter cartridges gas distributors fuses filters 2 Equipment that has been modified by an unauthorized party improperly installed improperly operated or misused based upon industry standards In the event of a claim under this warranty the remedies shall be at the discretion of Thermal Dynamics Corporation 1 Repair of the defective product 2 Replacemen
107. tops ACTION Connect work cable to workpiece Set output amperage ACTION RESULT Torch moved away from work while System is ready still activated for operation RESULT Main arc stops Pilot arc automatically ACTION restarts Protect eyes and activate torch RESULT PILOT ARC Gas flows briefly then stops Gas restarts ACTION Torch moved within transfer distance of workpiece RESULT DC indicator ON Pilot arc established Main arc transfers Pilot arc off ACTION Release torch trigger RESULT ACTION ACTION Main arc stops Unplug input Gas flow stops after post flow ON OFF switch power cord or to OFF O open external disconnect RESULT RESULT All indicators off No power to system ower supply fan s shuts off Art A 03706 APPENDIX A 2 Manual 0 2957 TP4 TP2 TP1 Logic 1 1 1 2 P1 3 P1 4 P1 5 P1 6 P1 7 P1 8 P1 9 P1 10 P1 11 P1 12 P1 13 P1 14 P1 15 P1 16 P1 17 P1 18 P1 19 P1 20 P1 21 1 22 1 23 1 24 1 25 1 26 Manual APPENDIX 3 LOGIC PC BOARD LAYOUT D13 D TDC 2003 R41 H2 LOGIC PCB ASSY R42 C21 D21
108. uds on the bottom flange of the Heatsink Shroud Remove the Heatsink Shroud as follows a Use the open left end of the Heatsink Shroud and the Pressure Switch Solenoid opening as handles b Pull the Heatsink Shroud away from the cen ter chassis and then up It may be necessary to pry the top and bottom flanges of the Heat sink Shroud slightly to release them from their mounting studs Movement will be limited by the wiring harness Manual 0 2957 G Main Transformer Removal and Replacement 1 2 Disengage the Heatsink Shroud per Paragraph H Disconnect wires 27 and 22 connected to termi nals E27 and E32 on the Main Power PC Board Pull these wires through the hole in the center chassis Remove the transformer a Lift the Main Transformer slightly Swing its left edge away from the center chassis Pull its right edge away from the center chassis b Lift it out of the Power Supply through the opening at the rear of the Power Supply Position the replacement Main Transformer be hind the Heatsink Shroud Assembly Position its wires atthe right edge as you face it of the trans former Install the replacement transformer as follows a Pass the tabs on the right edge of the base of the transformer into slots in the center chassis of the Power Supply b Swingthetransformer against the chassis and pass the tabs on the left edge of the base into slots in the chassis Press the transformer downward to
109. ugh the lower hole 2 Route wires as follows a Pass the red wires from the output inductor through the upper hole in the right rear edge of the Heatsink Shroud b Pass the black wires from the output inductor through the lower hole in the right rear edge of the Heatsink Shroud Refer to Appendix 11 Power Output Board Layout c Pass the wires from the temperature switch on the Output Inductor through the upper hole in the Shroud 3 Re install the Heatsink Shroud as follows a Lift the Heatsink Shroud Assembly into po sition Studs on the Power Supply base pass through holes in the bottom flange of the Shroud b Swing the top edge of the Shroud Assembly into place Studs on the Center Chassis of the Power Supply pass through holes in the top flanges of the Shroud c Ensure that the rubber feet on the Main Trans former engage holes in the Shroud 5 11 REPLACEMENT PROCEDURES d Puthex nuts on the studs Tighten the nuts on the right rear top and bottom studs Leave the nuts on the left forward studs loose tem porarily 4 Put the Fan Assembly in place per subsection 5 08 C Reconnect the work cable to terminal E61 on the Power Output PC Board 5 Tighten the nuts securing the left edge of the Heat sink Shroud Assembly The stud and nut on the bottom left edge fasten a wire stay to the Power Supply 6 Replace the grommets around the wire harnesses passing through the right rearward edge of t
110. uincy MA 02269 10 Norme 51B de la NFPA LES PROC D S DE COUPE ET DE SOUDAGE disponible aupres de la National Fire Protection Association Batterymarch Park Quincy MA 02269 11 Brochure GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIM S EN CYLINDRES disponible aupr s de l Association des Gaz Comprim s Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 Norme CSA W117 2 CODE DE S CURIT POUR LE SOUDAGE LA COUPE disponible aupr s de l Association des Normes Canadiennes Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 Livret NWSA BIBLIOGRAPHIE SUR LA S CURIT DU SOUDAGE disponible aupr s de l Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 14 Norme AWSFA 1 de l Association Am ricaine de Soudage RECOMMANDATIONS DE PRATIQUES SURES POUR LA PREPARATION A LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERM DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 Norme ANSI Z88 2 PRATIQUES DE PROTECTION RESPIRATOIRE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 GENERAL INFORMATION 1 6 Manual 0 2957 1 07 Declaration of Conformity Manufacturer Thermal Dynamics Corporation Address 82 Benning Street West Lebanon New Hamps
111. ure Switch PS1 Main Contactor W1 Main Contactor W1 Not used Not used Manual 0 2957 J25 1 25 2 726 1 726 2 74 72 27 3 27 4 27 5 27 6 27 7 27 8 29 1 29 2 29 3 29 4 30 1 30 2 731 1 731 2 732 1 732 2 733 1 733 2 733 3 733 4 733 5 133 6 33 7 33 8 34 1 34 2 34 3 34 4 34 5 34 6 Gate Drive Gate Drive Gate Drive Gate Drive Pot High Pot Wiper Pot Low 12V AC Gas Overtemp DC IGBT Heatsink Temp IGBT Heatsink Temp Jumper Jumper Gate Drive Gate Drive Gate Drive Gate Drive Inductor Temp Switch Inductor Temp Switch Out Sense DC Com Tip Sense t 12 vdc CSR ISense Not used Tip volts PIP Return PIP Not used Not used Torch Switch Return Torch Switch Manual 0 2957 43 1 J43 2 J43 3 J43 4 J43 5 J43 6 J43 7 J43 8 J43 9 J43 10 J43 11 J43 12 J43 13 J43 14 J43 15 J43 16 J43 17 J43 18 J43 19 J43 20 J43 21 J43 22 J43 23 J43 24 J43 25 J43 26 J43 27 J43 28 J43 29 J43 30 J43 31 J43 32 J43 33 J43 34 J43 35 J43 36 TP1 TP4 A 5 12 vdc to Logic PCB 12 vdc to Logic PCB DC Com DC Com MC1 On Tip Sense Run Set Pressure Good Overtemp CSR Gas on DCOK OVTEMP AC OK Torch Switch Torch Switch Return t 12 vdc POT High POT Wiper POT Low Gate Drive B Return Gate Drive B Gate Drive A Return Gate Drive A Out Sense Current Sense Current Sense Current Sense Return Current Sen
112. ure de la fum e et des gaz pouvant poser des dangers de sant Pour des informations sur la mani re de tester la fum e et les gaz de votre lieu de travail consultez l article 1 et les documents cit s la page 5 Utilisez un quipement sp cial tel que des tables de coupe d bit d eau ou courant descendant pour capter la fum e et les gaz N utilisez pasle chalumeau au jet de plasma dans une zone se trouvent des mati res ou des gaz combus tibles ou explosifs Le phosg ne un gaz toxique est g n r par la fum e provenant des solvants et des produits de nettoyage chlor s Eliminez toute source de telle fum e Ceproduit dans le proc der de soudage et de coupe produit de la fum e ou des gaz pouvant contenir des l ments reconnu dans L tat de la Californie qui peuvent causer des d fauts de naissance et le cancer La s curit de sant en Californie et la code s curit Sec 25249 5 et seq ELECTRIQUE Les chocs lectriques peuvent blesser ou m me tuer Le proc d au jet de plasma requiert et produit de l nergie lectrique haute tension Cette nergie lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres personnes sur le lieu de travail GENERAL INFORMATION 14 e Netouchez jamais une pi ce sous tension ou vive portez des gants et des v tements secs Isolez vous de la pi ce de travail ou des autres parties du circuit d
113. ut contactor W1 stuck a Check contactor Replace if stuck B Main power line fuses blow immediately after the ON OFF Switch is turned on 1 Faulty Input Diode a Test Input Diode per Subsection 4 10 C repair as necessary 4 5 TROUBLESHOOTING C Fans donot operate all control panel indicators OFF 1 Front Panel ON OFF switch in OFF position a Placeswitch to ON up position 2 Main power disconnect open a Close main power disconnect 3 Torch is not properly connected to Power Supply a Check torch connections to Power Supply Tighten or adjust as needed 4 Shield cup not fully tightened on torch head a Check shield cup for proper installation Do not overtighten 5 Main power line fuses blown a Replace main power line fuses J23 J24 J34 J32 J29 6 Improper input power cable connections inside Power Supply a Refer to System Schematic and correct if needed 7 Defective input power cable a Replaceinput power cable 8 Fuseblown inside Power Supply a Replace internal Fuse per Subsection 5 06 A 9 Line voltage above 10 tolerance over voltage protec tion a Reduce line supply 10 Faulty Auxiliary Transformer refer to Appendix pages 28 VAC Circuit Diagram Measure for 28 VAC on Main PC Board from J23 1 to J23 3 a If voltage is not present replace the Main PC Board J33 J18 J16 jf i 328 ifm
114. voltage condition exists 1 IfACindicator on Front Panel is OFF check for proper AC input voltage between input cables on the Main Contactor Input voltage should be as shown in the following chart If not check for proper voltage at the main power source TP1 Manual 0 2957 2003 29 pe R42 H2 LOGIC PCB ASSY mm 032 n2 TP amp 58 R2 921 055 m s 1 i R23 R43 R44 D4 a RA 84 Rae us ci 055 us ne 271 99 DN us R87 Os R25 1 Rol 5 da P1 7 Diy Reg D36 94 016 2 ka nU R72 c45 R27 za Hn C23 652 IL Ci R4B R74 L R90 P1 9 n b e Lu L 22 29 912 28 D3 D41 psi

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