Thermal Dynamics 51 cutmaster Service Manual

51

™

CUTMASTER

PLASMA CUTTING SYSTEM

Service Manual

Art # A-04611

Rev. AB.02 Date: June 15, 2007 Manual # 0-2972
Operating Features:

W ARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operat­ing, 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™ 51
Service Manual Number 0-2972

Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

www.thermal-dynamics.com

Copyright 2004, 2005, 2006 by
Thermadyne Corporation

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the pub­lisher is prohibited.

The publisher does not assume and hereby disclaims any 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: June 15, 2007

Record the following information for Warranty purposes:

Where Purchased:_______________________________ _______________

Purchase Date:_________________________________________________

Power Supply Serial #:___________________________ _______________

Torch Serial #:___________________________________ ______________

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ................................................................................................ 1-1

1.01 Notes, Cautions and Warnings ...................................................................... 1-1

1.02 Important Safety Precautions ....................................................................... 1-1

1.03 Publications .................................................................................................. 1-2

1.04 Note, Attention et Avertissement .................................................................. 1-3

1.05 Precautions De Securite Importantes ........................................................... 1-3

1.06 Documents De Reference ............................................................................. 1-5

1.07 Declaration of Conformity ............................................................................. 1-7

1.08 Statement of Warranty .................................................................................. 1-8

SECTION 2:

INTRODUCTION ............................................................................................................... 2-1

2.01 Scope Of Manual ......................................................................................... 2-1

2.02 General Service Philosophy ......................................................................... 2-1

2.03 Service Responsibilities ............................................................................... 2-1

SECTION 3: DESCRIPTION ................................................................................................... 3-1

3.01 Scope .......................................................................................................... 3-1

3.02 Power Supply Specifications ........................................................................ 3-1

3.03 Power Supply Features ................................................................................. 3-2

3.04 Air Regulator/Filter Assembly Specifications ................................................ 3-4

SECTION 4:

TROUBLESHOOTING ....................................................................................................... 4-1

4.01 Introduction ................................................................................................... 4-1

4.02 Periodic Inspection & Cleaning Procedures ................................................... 4-1

4.03 System Theor y ............................................................................................. 4-1

4.04 Common Operating Problems ....................................................................... 4-2

4.05 Troubleshooting Guide - General Information ................................................. 4-3

4.06 Circuit Fault Isolation .................................................................................... 4-4

4.07 Main Input and Internal Power Problems ....................................................... 4-5

4.08 Pilot Arc Problems ....................................................................................... 4-11

4.09 Main Arc Problems ...................................................................................... 4-14

4.10 Test Procedures ...........................................................................................4-15

SECTION 5:

REPLACEMENT PROCEDURES ...................................................................................... 5-1

5.01 Introduction ................................................................................................... 5-1

5.02 Anti-Static Handling Procedures ................................................................... 5-1

5.03 Parts Replacement - General Information ..................................................... 5-1

5.04 Major External Parts Replacement ............................................................... 5-2

5.05 Front Panel Parts Replacement..................................................................... 5-2

5.06 Left Side Internal Parts Replacement ........................................................... 5-3

5.07 Rear Panel Parts Replacement ..................................................................... 5-8

5.08 Right Side Internal Parts Replacement ........................................................ 5-10

TABLE OF CONTENTS (continued)

SECTION 6:

PARTS LISTS ................................................................................................................... 6-1

6.01 Introduction ................................................................................................... 6-1

6.02 Ordering Information ..................................................................................... 6-1

6.03 Major External Replacement Parts ............................................................... 6-2

6.04 Front Panel Replacement Parts .................................................................... 6-3

6.05 Left Side Internal Replacement Parts ........................................................... 6-4

6.06 Right Side Internal Replacement Parts ........................................................ 6-6

6.07 Rear Panel Replacement Parts .................................................................... 6-8

6.08 Options and Accessories ............................................................................. 6-9

PATENT INFORMATION ........................................................................................................... 6-10

APPENDIX 1: INPUT WIRING REQUIREMENTS ..................................................................... A-1

APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ........................................... A-2

APPENDIX 3: LOGIC PC BOARD LAYOUT .............................................................................. A-4

APPENDIX 4: MAIN POWER PC BOARD LAYOUT.................................................................. A-6

APPENDIX 5: PILOT BOARD LAYOUT..................................................................................... A-8

APPENDIX 6: LED/POT PC BOARD LAYOUT .......................................................................... A-9

APPENDIX 7: IGBT CIRCUIT PC BOARD LAYOUT ............................................................... A-10

APPENDIX 8: INPUT DIODE PC BOARD LAYOUT ................................................................ A-11

APPENDIX 9: OUTPUT DIODE PC BOARD LAYOUT ............................................................ A-12

APPENDIX 10-A: MAIN PC BOARD WIRING (208/230-Volt units) .......................................... A-14

APPENDIX 10-B: MAIN PC BOARD WIRING (400-Volt and 460-Volt units) ............................ A-15

APPENDIX 11: 28VAC CIRCUIT DIAGRAM ........................................................................... A-16

APPENDIX 12: MAINTENANCE SCHEDULE ........................................................................ A-17

APPENDIX 13: TORCH PIN - OUT DIAGRAMS ...................................................................... A-18

APPENDIX 14: TORCH CONNECTION DIAGRAMS ............................................................... A-19

APPENDIX 15: SYSTEM SCHEMATIC (208/230-Volt Units) ................................................... A-20

APPENDIX 16: SYSTEM SCHEMATIC (400-Volt and 460-Volt Units) ..................................... A-22

APPENDIX 17: Publication History ......................................................................................... A-24

Global Customer Service Contact Information ..................................................... Inside Rear Cover

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These high­lights are categorized as follows:

NOTE

An operation, procedure, or background informa­tion which requires additional emphasis or is help­ful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may
cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may
cause injury to the operator or others in the oper­ating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DAN­GEROUS 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. Per­sons who work near plasma arc cutting applica­tions should consult their medical health profes­sional 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 in­structions before using the equipment. Call 1-603­298-5711 or your local distributor if you have any
questions.

GASES 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.
Keep 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 met­als which may contain one or more of the follow­ing:

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 in­formation 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 com­bustible 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 de­fects and, in some cases, cancer. (California Health
& Safety Code Sec. 25249.5 et seq.)

ELECTRIC 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 op­erator or others in the workplace.

• Never touch any parts that are electrically “live”
or “hot.”

Manual 0-2972 1-1 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, Publica­tions.

• Disconnect power source before performing any
service or repairs.

• Read and follow all the instructions in the Operat­ing Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.

• Be sure there is no combustible or flammable ma­terial 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 a fire 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 under­water or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dis­sipated. Trapped hydrogen gas that is ignited will
cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc pro­cesses can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent per­manent loss of hearing.

• To protect your hearing from loud noise, wear pro­tective ear plugs and/or ear muffs. Protect others
in the workplace.

• Noise levels should be measured to be sure the deci­bels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual.

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 hel­met or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to pro­tect 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. Shade 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 work­piece.

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 Docu­ments, U.S. Government Printing Office, Washington,
D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding So­ciety, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable
from the Superintendent of Documents, U.S. Govern­ment Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU­PATION AND EDUCATIONAL EYE AND FACE PRO­TECTION, obtainable from American National Stan­dards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the Ameri­can National Standards Institute, 1430 Broadway, New
York, NY 10018

GENERAL INFORMATION 1-2 Manual 0-2972

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtain­able from American National Standards Institute, 1430
Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CON­TAINERS WHICH HAVE HELD COMBUSTIBLES, ob­tainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO­CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Associa­tion, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PRO­CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM­PRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELD­ING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Associa­tion, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM­MENDED SAFE PRACTICES FOR THE PREPARA­TION FOR WELDING AND CUTTING OF CONTAIN­ERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126

ATTENTION

Toute procédure pouvant résulter
l’endommagement du matériel en cas de non­respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.

1.05 Precautions De Securite
Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018

1.04 Note, Attention et

Avertissement

Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des
informations à caractère important. Ces mises en relief
sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.

Manual 0-2972 1-3 GENERAL INFORMATION

Il faut communiquer aux opérateurs et au person­nel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous
les avertissements, toutes les précautions de sécurité
et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votre distributeur
local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.

• Eloignez toute fumée et gaz de votre zone de respira­tion. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air
si l’aération fournie ne permet pas d’éliminer la fumée
et les gaz.

• Ne touchez jamais une pièce “sous tension” ou “vive”;
portez des gants et des vêtements secs. Isolez-vous
de la pièce de travail ou des autres parties du circuit
de soudage.

• Réparez ou remplacez toute pièce usée ou
endommagée.

• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un ou
plusieurs des éléments suivants:

antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des gaz
pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une
zone où se trouvent des matières ou des gaz combus­tibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.

• Ce produit, dans le procéder de soudage et de coupe,
produit de la fumée ou des gaz pouvant contenir des
éléments reconnu dans L’état de la Californie, qui
peuvent causer des défauts de naissance et le cancer.
(La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)

CHOC ELECTRIQUE

• Prenez des soins particuliers lorsque la zone de tra­vail est humide ou moite.

• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la page
5, article 9.)

• Débranchez l’alimentation électrique avant tout tra­vail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de
consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories
chaudes, des étincelles ou de l’arc de plasma. Le procédé
à l’arc de plasma produit du métal, des étincelles, des
scories chaudes pouvant mettre le feu aux matières com­bustibles ou provoquer l’explosion de fumées
inflammables.

• Soyez certain qu’aucune matière combustible ou in­flammable ne se trouve sur le lieu de travail. Protégez
toute telle matière qu’il est impossible de retirer de la
zone de travail.

• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans
une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous
les pièces de travail en aluminium lorsqu’elles sont
coupées sous l’eau ou sur une table d’eau. NE PAS
couper les alliages en aluminium sous l’eau ou sur
une table d’eau à moins que le gas hydrogène peut
s’échapper ou se dissiper. Le gas hydrogène accumulé
explosera si enflammé.

Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’énergie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.

GENERAL INFORMATION 1-4 Manual 0-2972

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser
vos yeux et brûler votre peau. Le procédé à l’arc de
plasma produit une lumière infra-rouge et des rayons

ultra-violets très forts. Ces rayons d’arc nuiront à vos
yeux et brûleront votre peau si vous ne vous protégez
pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou
un écran de soudeur. Portez toujours des lunettes de
sécurité munies de parois latérales ou des lunettes de
protection ou une autre sorte de protection oculaire.

• Portez des gants de soudeur et un vêtement protecteur
approprié pour protéger votre peau contre les
étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection
en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant des
cabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans le
recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE
PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superin­tendent 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 TRA­VAIL ET DANS LES ECOLES, disponible de l’Institut
Américain des Normes Nationales (American Na­tional Standards Institute), 1430 Broadway, New York,
NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. Vous dú4ez vous protéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres personnes
se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que
les décibels (le bruit) ne dépassent pas les niveaux
sûrs.

• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES
LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET
DE SOUDAGE, disponible auprès de l’American Na­tional Standards Institute, 1430 Broadway, New York,
NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS AYANT RENFERMÉ DES PRODUITS
COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126

8. Norme 51 de l’Association Américaine pour la Pro­tection contre les Incendies (NFPA), LES SYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la Na­tional Fire Protection Association, Batterymarch Park,
Quincy, MA 02269

Manual 0-2972 1-5 GENERAL INFORMATION

9. Norme 70 de la NFPA, CODE ELECTRIQUE NA­TIONAL, disponible auprès de la National Fire Pro­tection Association, Batterymarch Park, Quincy, MA
02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de la
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Stan­dards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA
SÉCURITÉ DU SOUDAGE, disponible auprès de
l’Association Nationale de Fournitures de Soudage
(National Welding Supply Association), 1900 Arch
Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRÉPARATION À LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT RENFERMÉ DES PRODUITS
DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018

GENERAL INFORMATION 1-6 Manual 0-2972

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street

West Lebanon, New Hampshire 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" (Euro­pean Council Directive 89/336/EEC) 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 Product Standard 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 S mark conform to EN50192

when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

* Extensive 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 0-2972 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
practice, 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

Product

Power Supply Components

(Parts and Labor)

Torch and Leads

(Parts and Labor)
CUTMASTER™ 51 3 Years 1 Year
CUTMASTER™ 81 3 Years 1 Year
CUTMASTER™ 101 3 Years 1 Year

This warranty does not apply to:

1. 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. Replacement 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 the Thermal Dynamics product is sold by non - authorized persons.

Effective January 15, 2004

GENERAL INFORMATION 1-8 Manual 0-2972

SECTION 2:

2.03 Service Responsibilities

INTRODUCTION

2.01 Scope Of Manual

This manual provides service instructions for the Ther­mal Dynamics CutMaster 51 Plasma Cutting Power Sup­ply. 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 tech­nicians familiar with this equipment.

For setup of this equipment, individual operating proce­dures, and basic troubleshooting, refer to Operating
Manual (0-2971).

Read both the operating manual and the service manual
thoroughly. A complete understanding of the capabili­ties and functions of this equipment will assure obtain­ing the performance for which it was designed.

2.02 General Service Philosophy

Several key points are essential to properly support the
application and operation of this equipment.

The service technician should be familiar with the equip­ment and its capabilities and should be prepared to rec­ommend arrangements of components which will pro­vide the most efficient layout, utilizing the equipment to
its best possible advantage.

Maintenance work should be accomplished in a timely
manner. If problems are encountered, or the equip­ment does not function as specified, contact the Tech­nical Services Department at West Lebanon, NH for
assistance (1-603-298-5711).

A. Application

The equipment should satisfy the customer’s require­ments 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 selec­tion 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 mali­cious 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.

Manual 0-2972 2-1 INTRODUCTION

This Page Left Blank

INTRODUCTION 2-2 Manual 0-2972

SECTION 3: DESCRIPTION

w

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 oper­ating 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 51 Power Supply Specifications

208 / 230 V A C (187 - 253 VA C), Single P has e, 60 Hz

Input Power

Input Power Cable

Output Current

Power Supply Gas

Filtering Ability

Ambi ent Temperature

All Units

* NOTE: The duty cycle will be reduced i f the pri m ary i nput power (AC) is l o

400 VA C (360 - 440 VAC), Three Phase, 50/60 Hz
460 VA C (414 - 506 VAC), Single P has e, 60 Hz
460 VA C (414 - 506 VAC), Three Phase, 60 Hz
Power Supply inc l udes i nput cable.
Cable for 208/230V input power inc l udes m ol ded plug.
20 - 40 Amps, Conti nuous l y Adjustable

Part iculat es to 20 Mic rons

CutMaster 51 Power Supply Duty Cycle *

40° C (104° F)

IEC

Rating
Duty Cycle
Current
DC Volt age

or the output voltage (DC) is higher t han s hown in this c hart .

40 Amps n/a 25 Amps n/a n/ a n/a

96 vdc n/a 90 vdc n/a n/a n/a

TDC

Rating

40% 60% 100%

IEC

Rating

TDC

Rating

IEC

Rating

TDC

Rating

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. To 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 0-2972 3-1 DESCRIPTION

NOTE:

3.03 Power Supply Features

Handle and Leads Wrap

Art # A-03578

Control Panel

Torch Leads Receptacle

Gas Pressure Regulator /

Ports for Optional Automation
Interface Cable

Gas Pressure Gauge

Work Cable
and Clamp

Filter Assembly

Gas Inlet Port

DESCRIPTION 3-2 Manual 0-2972

Art # A-03738

Input Power Cord

1. Front Panel Controls and Features

• Main Power ON

• RUN

/ OFF Switch

/RAPID AUTO RESTART SET Switch

• 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.

2. Front Panel Indicators

• AC When lighted, indicates AC input power is present in thepower supply.

• TEMP When lighted, indicates the power supply is overheated.

• GAS When lighted, indicates that adequate input air pressure for power supply operation is present.

• DC 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

10.75"

273 mm

A-03700

16.375"

416 mm

58 lb / 26 kg

22.5"

0.57 m

Manual 0-2972 3-3 DESCRIPTION

3.04 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)

DESCRIPTION 3-4 Manual 0-2972

SECTION 4:

4.03 System Theory

TROUBLESHOOTING

4.01 Introduction

This section provides service diagnostics for the CutMas­ter 51 Power Supply, allowing the Technician to isolate
any faulty subassemblies. Refer to Section 5, Repairs &
Replacement Procedures, for parts replacement instruc­tions.

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 fac­tory 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 for
those products.

4.02 Periodic Inspection & Cleaning
Procedures

WARNING

Disconnect primary power and bleed down the sys­tem before disassembling the torch, leads, or power
supply.

A. Logic PC Board Functions

The Logic PC Board controls the timing and sequenc­ing 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.

The GAS indicator
gas pressure in the power supply to enable power sup-

ply operation.

Minimum gas pressure for power supply operation
is lower than the minimum for torch operation.

When the unit is at “idle” the AC indicator on
the Front Panel should be ON. When the torch is acti­vated, the gas begins to flow. After a brief preflow, the
INV ON signal is given, and the DC indicator on
the Front Panel turns ON.

An open circuit voltage of approximately 230 to 300 vdc
(depending on input 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 volt­age. When the output voltage drops below 60 vdc, indi­cating a problem exists, the Logic PC Board sends a sig­nal which turns OFF the INV ON Enable signal. This
happens in less than 50 milliseconds.

is ON when there is sufficient

NOTE

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 pro­cedures.

Manual 0-2972 4-1 TROUBLESHOOTING

When the torch is activated, gas will flow for approxi­mately two seconds before DC is established (indi­cated 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.

4.04 Common Operating Problems

WARNINGS

Disconnect primary power at the source before dis­assembling the power supply, torch, or torch leads.

Frequently review the Important Safety Precau­tions in Section 1. Be sure the operator is equipped
with proper gloves, clothing, and eye and ear pro­tection. 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.

E. Dross

When dross is present on carbon steel, it is commonly
referred to as either “high speed, slow speed, or top
dross”. Dross present on top of the plate is normally
caused by too great a torch to plate distance. "Top
dross" is normally very easy to remove and can often
be wiped off with a welding glove. "Slow speed dross"
is normally present on the bottom edge of the plate.
It can vary from a light to heavy bead, but does not
adhere tightly to the cut edge, and can be easily
scraped off. "High speed dross" usually forms a nar­row bead along the bottom of the cut edge and is very
difficult to remove. When cutting a troublesome steel,
it is sometimes useful to reduce the cutting speed to
produce "slow speed dross". Any resultant cleanup
can be accomplished by scraping, not grinding.

F. Parts - In - Place Circuit

Handle torch leads with care and protect them from
damage.

A. Piloting

Piloting is harder on parts life than actual cutting be­cause the pilot arc is directed from the electrode to
the tip rather than to a workpiece. Whenever pos­sible, avoid excessive pilot arc time to improve parts
life.

B. Torch Standoff

Improper standoff (the distance between the torch tip
and workpiece) can adversely affect tip life as well as
shield cup life. Standoff may also significantly affect
the bevel angle. Reducing standoff generally results
in a more square cut.

C. Edge Starting

For edge starts, hold the torch perpendicular to the
workpiece with the front of the torch tip at the edge
of the workpiece, not touching, at the point where the
cut is to start. When starting at the edge of the plate,
do not pause at the edge and force the arc to “reach”
for the edge of the metal. Establish the cutting arc as
quickly as possible.

D. Direction of Cut

The plasma gas stream swirls as it leaves the torch.
The purpose of the swirl is to maintain a smooth col­umn of gas. The swirl effect results in one side of a
cut being more square than the other. Viewed along
the direction of travel, the right side of the cut is more
square than the left.

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 in­stalled, 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.

G. Common Cutting Faults

1. Insufficient Penetration

a. Cutting speed too fast

b. Torch tilted too much

c. Metal too thick

d. Worn torch parts

e. Cutting current too low

f. Non-Genuine Thermal Dynamics parts used

2. Main Arc Extinguishes

a. Cutting speed too slow

b. Torch standoff too high from workpiece

c. Cutting current too high

d. Work cable disconnected

e. Worn torch parts

f. Non-Genuine Thermal Dynamics parts used

TROUBLESHOOTING 4-2 Manual 0-2972

3. Excessive Dross Formation

The troubleshooting guide has subsections as follows:

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. Gas pressure too low

e. Improperly assembled torch

f. Incorrect torch parts for the operation

g. Non-Genuine Thermal Dynamics parts used

4.05 Troubleshooting Guide ­General Information

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 in­dicator status identification tables. The subsection is ref­erenced by the troubleshooting guide for the specific test
to be performed. The Power Supply is available for sev­eral 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 iso­late problem to possible circuit(s) per Subsection 4.06,
Circuit Fault Isolation.

WARNING

There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
power electronics measurement and troubleshoot­ing techniques.

A. General Information

This Section covers advanced troubleshooting, which re­quires power supply disassembly and live measurements.
Advanced troubleshooting and repair of this unit is a pro­cess which should be undertaken only by those familiar
with high voltage high power electronic equipment.

If major complex subassemblies are faulty, the faulty sub­assembly must be returned for repair.

NOTE

Follow all instructions as listed and complete each
in the order presented.

2. Determine symptom and isolate to defective assem­bly using the following format:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

a. Check/Remedy (Text Type)

3. Locate your symptom in the appropriate Subsection.

4. Check the causes (easiest listed first) for the symptom.

5. Check the remedies listed for each cause.

6. Repair as needed being sure to verify that unit is fully
operational after any repairs.

NOTES

Many signals are transferred between Printed Cir­cuit Board Assemblies on Cables. If these cables
become faulty they can then cause various prob­lems. Do not forget about these cables when
troubleshooting.

While troubleshooting visually inspect the internal
components for signs of overheating, fractures and
damage.

Manual 0-2972 4-3 TROUBLESHOOTING

4.06 Circuit Fault Isolation

B. Initial Setup Conditions

A. Controls and Indicators

A

30

25

3

20

1

1. ON/OFF switch. This switch controls AC power to the
unit. Up is ON, down is OFF.

2. RUN / RAPID AUTO 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 op­erations. Down is SET, for setting gas pressure and
purging lines.

3. Current control knob (A) This control regulates cur­rent to the torch.

4. AC indicator When lit, indicates operating
power is present in the unit.

5. TEMP indicator turns on when internal sensors

detect temperatures above normal limits.

35

40

Art #A-03844

4

5

6

7

2

This section is to help isolate the defective circuit before
troubleshooting, identify symptoms, and test the unit for
proper operation. Follow the instructions as given to iden­tify 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. Connect gas supply to rear of Power Supply.

2. Turn on gas supply and set operating pressure per
pressure setting label on power supply.

NOTE

Minimum gas pressure for power supply operation
is lower than the minimum for torch operation.

3. Set the Power Supply controls as follows:

• ON/OFF switch to OFF (Down)

• RUN / RAPID AUTO RESTART / SET switch to
SET (Down)

• CURRENT control (A) to maximum

C. Main Input and Internal Power Tests

1. Connect main AC power to the unit.

2. Set the Power Supply 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 O FF

• GAS Indicator is ON if input pressure is suffi­cient for power supply operation.

NOTE

Minimum gas pressure for power supply operation
is lower than the minimum for torch operation.

6. GAS indicator Indicates adequate gas pressure
for power supply operation.

NOTE

Minimum gas pressure for power supply opera­tion is lower than the minimum for torch opera­tion.

7. DC indicator Indicates DC power output circuit
is active. (Torch must be activated).

TROUBLESHOOTING 4-4 Manual 0-2972

• DC indicator is OFF

• Gas flows

• Fan operates

3. 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.

D. Pilot Arc Test

Art # A-03939

Lower
screws

Ground wire

Lower
screws

Upper
screws

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:

• 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 cor­rect 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 work­piece. 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 work­piece to establish the main cutting arc, and note the fol­lowing:

3. Carefully lift the cover off the unit, and remove the nut
securing the ground wire to the side panel.

4. Re-install the cover by reversing the above steps.

• Main cutting 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 symp­tom 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 ac­cess to input power connections and test points.

Disconnect primary power at the source before as­sembling 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.

WARNING

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 il­lustrates wiring connections.

2. Main input contactor (W1) stuck.

a. Check contactor. Replace if stuck.

NOTE

There is a ground wire attached from the cover to
the main body of the unit.

Manual 0-2972 4-5 TROUBLESHOOTING

B. Main power line fuses blow immediately after the

ON/OFF Switch is turned on.

1. Faulty Input Diode

4. Shield cup not fully tightened on torch head.

a. Check shield cup for proper installation. Do

not overtighten.

a. Test Input Diode per Subsection 4.10-C; repair

as necessary.

C. Fans do not operate; all control panel indicators OFF

1. Front Panel ON/OFF switch in OFF position

a. Place switch 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.

Fuse

(F1)

J26

TP10

E1

E14

LT 1

J8

5. Main power line fuses blown

a. Replace main power line fuses.

6. Improper input power cable connections inside Power
Supply

a. Refer to System Schematic and correct if needed.

7. Defective input power cable

a. Replace input power cable.

8. Fuse blown inside Power Supply

a. Replace internal Fuse per Subsection 5.06-A.

9. Line voltage above 10% tolerance (over voltage protec­tion)

a. Reduce line supply.

J5

J4

TP1

J2

J23

J3

TP18

TP2

TP5

E2

E3

E12

E35

E30

TP14

E22

E11

E4

E31

J18

E28

Output

E7

E34

E19

Diode

E8

E39

E21

E29

E13

E15

E33

IGBT

E32

J19

J21

TP13

J20

E16

Main Printed Circuit Board Layout (logic board not shown)

E9

E38

E20

E27

E10

J1

E18

E23

E26

E5

E43

E36

E41

E6

Art #A-03751

J22

J9

E25

E24

E42

E37

E28

E40

E17

TROUBLESHOOTING 4-6 Manual 0-2972

10. Faulty Auxiliary Transformer (refer to Appendix pages,
28 VAC Circuit Diagram)

Measure for 28 VAC on Main PC Board from J5-1
to J5-3.

a. If voltage is not present, replace the Main PC

Board.

11. Faulty ON/OFF switch

Measure for 28 VAC on the Main PC Board be­tween J3-5 to J3-6.

a. If voltage is not present replace the ON/OFF

Switch.

12. Faulty Main PC Board

Measure for 12 vdc on Main PC Board

from TP5 to

TP1.

4. Faulty Temperature Sensor / Switch

a. Shut input power off. Check IGBT Heatsink

Temp Sensor (TS1). Disconnect wire connector
P2 from terminal J2 on Main PC Board. Check
connector pins 1 and 2 for 10K ohm (±25%) (at
ambient temperature). If resistance is not 10K
ohm (±25%), replace TS1.

b. Shut input power off. Check Inductor Temp

Switch (TS2). Disconnect wire connector P23
from terminal J23 on Main PC Board. Check
connector pins 1 and 2 for resistance. If resis­tance is greater than 12K ohms, replace output
inductor (L1). If temp switch is open, replace
Main PC Board.

E. No gas flow; RUN / RAPID AUTO RESTART /SET

switch in SET position; AC indicator ON;

a. If voltage is not present, replace the Main PC

Board.

D. Fan does not run; AC , GAS and TEMP

indicators ON, DC indicator off

A

Art # A-03984

1. Air flow through unit is restricted

a. Provide adequate air flow

2. Exceeded Duty Cycle of Power Supply

a. Deactivate torch and wait for fan to cool unit. Refer

to Specifications Section for proper duty Cycle for
this unit.

3. Faulty Fan

Measure for 230 VAC (±) on the Main PC Board
from J26-1 to J26-4.

• If voltage is correct, replace Fan (M1).

TEMP GAS and DC indicators OFF

A

Art # A-03985

1. Gas supply not connected to unit

a. Connect to gas supply.

2. Gas supply not turned on

a. Turn gas supply on.

3. Gas pressure too low

a. Adjust gas pressure per pressure setting label

on power supply.

4. Faulty RUN / RAPID AUTO RESTART / SET switch

a. Check continuity.

5. Faulty Gas Solenoid circuit

a. Test Gas Solenoid circuit per Subsection 4.10-F;

repair as necessary.

6. Faulty Logic Board

Manual 0-2972 4-7 TROUBLESHOOTING

a. Replace logic board.

F. RUN / RAPID AUTO RESTART /SET switch in

RUN or RAPID AUTO RESTART position; AC

indicator

ON; TEMP , GAS , and DC

indicators OFF

A

Art # A-03986

1. Gas pressure too low

a. Set operating pressure per pressure setting la-

bel on power supply.

P1-1 to P1-36

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
the unit.

a. 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.

b. If pressure is above 50 psi (3.4 bar) and 12 vdc is

not present, replace the Logic PC Board.

c. Remove one wire from the pressure switch.

Check for ± 0 vdc at Main PC Board pin 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.

P1-7

TP6

TP10

TP9

TP8

TP7

TP4

TP3

TP1

TP2

TP5

D8

TROUBLESHOOTING 4-8 Manual 0-2972

Art # A-03883

Logic Board Layout

G. Gas continues to flow with RUN / RAPID AUTO

RESTART / SET switch in RUN position.

1. Damaged gas solenoid.

I. Gas cycles on and off when power is turned on; AC

indicator flashes; TEMP indicator off,

a. Turn the front panel ON/OFF switch to OFF.

• If gas 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 recep­tacle J18. Check continuity through wire har­ness 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.

• If 0 vdc is present, replace Logic PCB.

H. Gas flows continuously when power is turned on;

AC indicator

flashes, TEMP indicator off,

GAS indicator ON, DC indicator off

A

GAS indicator

ON

A

Art # A-03987

1. Torch shield cup is loose.

a. Tighten shield cup by hand. Do not overtighten.

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 fit­ting does not move freely.

Art # A-03987

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 OFF. 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, remote
pendant control switch must also be closed.

Start Cartridge

Lower End Fitting

Art # A-03621

4. Shorted power supply torch receptacle

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 Main PC Board.

a. Turn Power Supply OFF. Bleed down the system.

Refer to Main PC Board Wiring Diagram. Check
Main PC Board for continuity between terminals E6
and E10. If continuity is found, replace Main PC
Board.

Manual 0-2972 4-9 TROUBLESHOOTING

E14

J8

LT 1

Fuse

(F1)

J26

TP10

TP18

TP2

J5

J4

TP1

J2

J23

J3

E1

E2

E3

E12

E35

E30

TP14

E22

E11

E4

E31

J18

IGBT

Output

Diode

J1

E18

E23

E26

E5

E43

E36

E41

E6

TP5

J22

J9

E25

E24

E42

E37

E28

E40

E17

E28

E29

E13

E15

E33

E32

J19

J21

TP13

E16

J20

E7

E34

E19

E8

E21

Main Printed Circuit Board Layout (Logic PCB Not Shown)

E39

E9

E38

E20

E27

E10

Art #A-03751

TROUBLESHOOTING 4-10 Manual 0-2972

4.08 Pilot Arc Problems

WARNING

3. Faulty IGBT

a. Measure between the following points on the Main

PC Board:

• E4 to E10

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 tech­niques.

Locate your symptom below:

A. Torch will not pilot; gas flows; AC indicator

ON, GAS , TEMP , and DC indicators

OFF

A

Art # A-03988

• E10 to E20

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 IGBT.

B. 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

A

Art # A-03990

1. Gas pressure is below power supply minimum require­ment

a. Adjust gas pressure per pressure setting label

on power supply.

2. Upper O-ring on torch head is in wrong position.

a. Remove shield cup from torch; check position of

upper O-ring. Correct if necessary.

Upper Groove
with Vent Holes
Must Remain Open

Upper O-Ring
in Correct Groove

Threads

Lower O-Ring

Art # A-03725

1. Gas pressure is below torch minimum requirement
(NOTE: Minimum pressure for power supply opera­tion is lower than minimum required for torch opera­tion.)

a. Adjust gas pressure per pressure setting label

on power supply.

2. Torch tip, starter cartridge, or electrode missing.

a. Turn off power supply. Remove shield cup, in-

stall missing parts.

Manual 0-2972 4-11 TROUBLESHOOTING

3. Torch starter cartridge is stuck

4. Faulty Temperature Sensor / Switch

a. Turn off 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. Worn or faulty torch parts

a. Inspect torch consumable parts. Replace if nec-

essary.

C. Torch will not pilot; AC

, TEMP , and

GAS indicators ON, DC indicator off

A

Art # A-03621

CAUTION

Turn off input power for the following tests.

a. Check IGBT Heatsink Temp Sensor (TS1). Dis-

connect wire connector P2 from terminal J2 on
Main PC Board. Check connector pins 1 and 2
for 10k ohm (± 25%) (at ambient temperature). If
resistance is not 10K ohm (±25%), replace TS1.

b. Check Inductor Temp Switch (TS2). Disconnect

wire connector P23 from terminal J23 on Main
PC Board. Check connector pins 1 and 2 for at
least 12K ohms. If resistance is less than 12K
ohms, replace output inductor (L1). If temp
switch is open, replace Main PC Board.

5. Faulty Logic PC Board

a. Check for (±) 12 vdc on Logic PC Board between

J1-9 and TP1. If (±) 0 vdc is present, replace
Logic PC Board.

6. Faulty Main PC Board

a. Check for (±) 0 vdc on Main PC Board between

J41-9 and TP1. If (±) 0 vdc is present, replace
Main PC Board.

7. Faulty Fan

Art # A-03989

1. Air flow blocked

a. Check for blocked air flow around the unit and

correct condition.

2. Unit is overheated

a. Let unit cool down for at least 5 minutes. Make

sure the unit has not been operated beyond Duty
Cycle limit. Refer to duty cycle data in Specifi­cations Section.

3. Input Line Voltage is low

a. Check and connect to proper input power line.

a. Measure for (±) 230VAC on Main PC Board from

J26-1 to J26-4.

• If voltage is correct, replace fan (M1).

TROUBLESHOOTING 4-12 Manual 0-2972

D. Gas flows; AC indicator and GAS indicators

a. Reset gas pressure per pressure setting label on

power supply.

ON; TEMP indicator off; DC indicator off or

blinks on/off once.

A

OR

Art # A-03991

1. Faulty IGBT or Output Diode Module Assembly.

a. Check per Subsection 4.10-C; repair as needed.

2. Faulty Main PCB

a. Test per Subsection 4.10-F; repair as needed.

E No arc or intermittent arc in torch; Gas flows;

AC , GAS and DC indicators ON;

TEMP indicator off

2. Oil/moisture in air lines

a. Put the ON / OFF switch in the ON (up) posi-

tion. Put the RUN / RAPID AUTO RESTART /
SET switch in the SET (down) position.

b. Place a welding filter lens in front of the torch

and turn on the air. Any oil or moisture in the
air will be visible on the lens. Do not start an

arc!

c. Purge system. If problem corrected, add filters

in line with air source.

3. Incorrect torch parts

a. Inspect the torch parts; replace as needed.

4. Faulty leads

a. Check torch leads continuity.

5. Faulty torch

a. Check torch.

6. Faulty connection of wire #58 or 62 to Pilot Board

a. Check wiring connection. Refer to the System

Schematic in the Appendix. Connections
should be:

• Wire #58 to Pilot Board terminal E58

A

Art # A-03992

1. Gas pressure set incorrectly (too high)

• Wire #62 to Pilot Board terminal E62

If wires 58 and 62 are not connected to the proper
terminals, replace the Pilot Board.

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.

8. Faulty Logic Board or Faulty Pilot Board

Manual 0-2972 4-13 TROUBLESHOOTING

a. Install a jumper between wires 58 and 62 on Pilot

Board and retry piloting. If torch pilots with jumper
installed, replace Pilot Board. If torch does not pilot,
replace Logic Board.

• If not, replace Main PC Board.

5. Faulty Main Input Contactor.

a. Check per Subsection 4.10-D.

4.09 Main Arc Problems

Locate your symptom below:

A. Main cutting arc will not start

1. Work cable not connected.

a. Connect work cable.

2. Holding too high of a standoff.

a. Refer to 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 Board Layout.

• If voltage goes to 0 vdc replace Output Board.

B. When operating the amperage drops off after the main

cutting arc starts.

1. Faulty Pilot Board

a. With power off and wires E58 and E62 disconnected

from the pilot board, measure for continuity between
terminals #E58 and #E62. If continuity is found, re­place Pilot Board.

P1-1 to P1-36

P1-7

TP6

TP4

TP10

TP9

TP8

TP7

TP3

TP1

TP2

TP5

D8

Art # A-03883

Logic Board Layout

TROUBLESHOOTING 4-14 Manual 0-2972

4.10 Test Procedures

Art # A-03939

Lower
screws

Ground wire

Lower
screws

Upper
screws

B. Opening Power Supply Enclosure

The test procedures in this subsection are referenced in
the troubleshooting section.

A. Safety Precautions

1. Significant DC Voltage exists after removal of input
power. Allow two minutes for discharge time. Voltage
measured on input capacitors must be zero before per­forming service on the power supply.

2. Do Not touch electrical components with any part of
the human body when power is applied.

3. Keep away from any moving parts.

4. Hot surfaces can cause severe burns. Allow equip­ment to cool before servicing.

5. 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.

6. Misaligned plugs can cause printed circuit board dam­age. Be sure plugs are properly aligned and completely
seated.

The cover of the Power Supply must be removed to gain
access to the input power connections.

WARNING

Disconnect primary power at the source before as­sembling 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.

3. Carefully lift the cover off the unit, and remove the nut
securing the ground wire to the side panel.

4. Re-install the cover by reversing the above steps.

7. Excessive pressure can damage printed circuit boards.
Use only minimal pressure and gentle movement when
disconnecting or connecting printed circuit board
plugs.

Manual 0-2972 4-15 TROUBLESHOOTING

C. Diode Testing Basics

Testing of diode modules requires a digital volt/ohm­meter 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. Locate the diode module to be tested.

2. Remove cables from mounting studs on diodes to iso­late the module.

3. Set digital volt/ohmmeter to diode test scale.

4. 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.

5. Connect the volt/ohmmeter positive lead to the anode
(+) of the diode and the negative lead to the cathode
(-) of the diode for forward bias testing (refer to follow­ing figure). A properly functioning diode will conduct
in the forward bias direction and indicate between 0.3
to 0.9 volts.

Art # A-00307

Art # A-00306

OL

Reverse Bias

Diode Not Conducting

Cathode

Anode

+

VR

COM

_

A

Testing Diode Reverse Bias

7. If a diode checks bad, replace the diode module.

0.75

Forward Bias

Diode Conducting

Diode Test Symbol

Anode

Cathode

+

VR

COM

_

A

Testing Diode Forward Bias

6. Reverse the meter leads across the diode for reverse
bias testing (refer to following figure). A properly func­tioning diode will block in the reverse bias direction
and depending on the meter function will indicate an
open or “OL”.

8. Reconnect all cables to proper terminals.

TROUBLESHOOTING 4-16 Manual 0-2972

D. Input Diode Test

E. Main Input Contactor (W1) Test

Check Input Diode for shorted input diode.

Remove AC power and with an ohmmeter set on the diode
range make the following checks on Main PC Board:

For 208/230V Power Supplies:

Meter (+ ) Meter (-) Indicatio n

E2 E11 Diode Drop
E11 E2 Open
E12 E2 Diode Drop

E2 E12 Open

For 400V and 460V Power Supplies:

Meter (+ ) Meter (-) Indicatio n

E1 E11 Diode Drop
E11 E1 Open

E2 E11 Diode Drop
E11 E2 Open

E3 E11 Diode Drop
E11 E3 Open
E12 E1 Di ode Drop

E1 E12 Open
E12 E2 Di ode Drop

E2 E12 Open
E12 E3 Di ode Drop

E3 E12 Open

The meter should indicate a diode drop in one direction
and an open in the other direction for each check.

If Input Bridge Diode is shorted, make the following checks
with an ohmmeter at the Main Contactor (W1):

Meter (+ ) Meter (-) Indicat io n

All

Voltages

400/460V

Only

L1 T1 Open
L2 T2 Open

L2 T1 Open

If any test has resistance, then replace the Main Contactor
also.

Reconnect power and observe proper start-up procedure.
AC Indicator on the Front Panel should be ON. If indica­tor is OFF there is no voltage to the Power Supply or an
overvoltage condition exists.

1. If AC Indicator is OFF, check for proper input AC
voltage at the Main Contactor. If voltage is not
correct (refer to following chart), check for proper
AC voltage at the main power source.

CutMaster 51 Input Contactor Vol tage Ranges

Input

Power

Test Points

Voltage

Range

208/230V L1, L2 187-253VAC

400V L1, L3 360-440VAC
460V L1, L3 414-506VAC

208/230V Power Supply Input Contactor:

Input
Cable (L1)

Input
Cable (L2)

Wire #12

Wire #11

Label

A-03223

400V and 460V Power Supply Input Contactor:

To E2

To E3

Connections to

Main PCB

To E1

T1 T2 T3

L1 L2 L3

Input Side

L3

L2

Label

Manual 0-2972 4-17 TROUBLESHOOTING

L1

#12

#11

Main Contactor

A-03224

2. Measure for approximately 28 VAC on coil of Con­tactor between wires #11 and #12.

2. Output Diode Circuit Test

• If voltage is correct, replace Main Contactor. If
voltage is incorrect, replace Main PC Board.

F. Gas Solenoid Circuit Test

Make the following voltage checks and replace the faulty
part as required.

1. Place the RUN/RAPID AUTO RESTART/SET
Switch to the SET position.

2. Measure for 28VAC across Solenoid wires #7 and
#8.

• If 28VAC is present, replace Solenoid/Pressure
Switch Assembly. If 28VAC is not present, go to
the next step.

3. Check voltage at J1-14 to TP1 on Logic Board.

• If less than 2vdc replace Main Power PC Board.
If more than 2vdc, replace Logic PC Board.

G. IGBT Board/Output Diode Circuit Test

1. No DC Output

When the unit is at “idle” the AC indicator on the
Front Panel should be ON. When the torch is acti­vated, the gas begins to flow. When the preflow time is
over, the INV ON indicator on the Logic PCB energizes,
and the DC indicator on the Front Panel turns ON.

WARNING

Disconnect primary power at the source before tak­ing any resistance checks.

a. Use an ohmmeter set to the diode function and make

the following measurements on the Output Diode
Board to Main Power PC Board.

Meter (+ ) Meter (-) I n d icatio n

E18 E21 Diode Drop
E21 E18 Open
E18 E20 Diode Drop
E20 E18 Open
E20 E19 Diode Drop
E19 E20 Open
E21 E19 Diode Drop
E19 E21 Open
E18 E19 (2) Diode Drops
E19 E18 Open

b. The meter should indicate a diode drop in one di-

rection and an open in the other direction for each
check. Replace Output Diode Board if readings are
not the same as the chart.

• If the INV ON indicator does not turn ON, then
replace the Logic PCB.

• If the INV ON indicator turns ON then OFF imme­diately, the following test should be performed:

a. Disconnect eight-pin wire harness connector

from the Pilot PC Board.

WARNING

The connector on the Pilot PC Board must be dis­connected to prevent electrical damage to measur­ing equipment when testing the open circuit volt­age (OCV).

b. Activate torch (Logic PC Board Inverter On In-

dicator, turns ON).

c. Measure for more than 200 vdc between E7(+)

and E10 (-) on the Main PC Board. If voltage is
less than 10 vdc, each IGBT Module and Out­put Diode Module should be tested individu-
ally.

TROUBLESHOOTING 4-18 Manual 0-2972

3. IGBT Circuit Test

4. Gate Drive & DC Sensing

a. Use an ohmmeter set to the diode function and make

the following measurements on the IGBT Board to
the Main Power Board.

CM51 IGBT Test Indi ca tion

208/230V

Power Supply

Met e r (+) M eter (-) M eter (+ ) Met er (-) Indic ation

E3 E 13 E35 E 13 Di ode Drop
E13 E3 E13 E35 Open
E15 E3 E15 E 35 Diode Drop

E3 E15 E35 E15 Open
E15 E 13 E15 E 13 (2) Diode Drops
E13 E15 E13 E15 Open

400V & 460V

Power Supply

s

b. The meter should indicate a diode drop in one di-

rection and an open in the other direction for each
check. Replace IGBT Board if readings are not the
same as the chart.

c. Activate the torch.

• After two seconds INV ON indicator on the
Logic PCB should turn ON. If indicator does
not turn ON, replace Logic PCB.

d. Measure open circuit voltage between E7(+) to E10

(-) on the Main Power PC Board. Voltage should be
greater than 200 vdc. If voltage is less than 10 vdc,
refer to the output diode test measurements or IGBT
module test measurements or shorted torch mea­surements.

a. After checking all previous steps in Subsection

4.09-G, jumper TP1 to TP2 on the Logic PCB.

b. Disconnect wires from the Main PC Board as shown

in the chart. When the unit is turned on, the DC
light should remain ON.

Main P C B oard W i re Disconnec tion Poi nt s

208/230V Unit s E 3, E13, E 15

400, 460V Unit s E13, E 15, E35

c. Activate the torch (press torch switch on the handle,

send START signal from CNC Control or press the
torch switch on the Remote Pendant). After two sec­onds INV ON indicator on the Logic PCB should
come on and remain on.

• If INV ON indicator does not remain on, replace
Logic PCB.

• If INV ON indicator does remain on, then check
for approximately 6 vdc between J1-29 and J1­28 and between J1-27 and J1-26.

• If no voltage, replace Logic PC Board.

• If voltage is correct, measure for approxi-

mately 6 vdc between E32 to TP-14 on the
IGBT PCB and E31 to TP13 on IGBT PC
Board.

• If 0 vdc, replace Main PC Board.

• If correct, reconnect wires to Main PC
Board.

d. With jumper between TP1 to TP2 still in place, acti-

vate the torch and measure for 230 vdc to 300 vdc at
Main PCB E18 to E19. Refer to Appendix 4-A or 4-B.

Manual 0-2972 4-19 TROUBLESHOOTING

• If 0 vdc, replace IGBT PC Board.

• If correct, replace Logic PC Board.

This completes the test procedures.

This Page Left Blank

TROUBLESHOOTING 4-20 Manual 0-2972

SECTION 5:

REPLACEMENT

PROCEDURES

5.01 Introduction

This section describes parts replacement procedures and
all repairs which may be performed on the CutMaster 51
Power Supply.

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

B. Procedure

1. Open the wrist strap and unwrap the first two folds
of the band. Wrap the adhesive side firmly around
your wrist.

2. Unroll the rest of the band and peel the liner from
the copper foil at the opposite end.

3. Attach the copper foil to a convenient and exposed
electrical ground.

4. Connect the equipment primary cable ground to
the same electrical ground as the wrist strap.

5. Open the equipment enclosure and remove the
failed PC board.

6. Carefully open the ESD protective bag and remove
the replacement PC Board.

7. Install the replacement PC Board in the equipment
and make all necessary connections.

A. General

Caution: PC Boards can be irreparably damaged by im­proper handling due to electrostatic discharge (ESD).

Replacement PC Boards are shipped in a protective en­closure to prevent damage from electrostatic discharge
(ESD) during shipping. Included with each replacement
board is a ground strap to prevent static damage during
installation.

WARNINGS

Read and understand these instructions and the
instructions on the grounding wrist strap package
before opening the equipment enclosure or remov­ing the replacement PC board from its protective
enclosure.

Disconnect primary power to the system before dis­assembling the torch, torch leads, or power supply
enclosure.

Where these instructions include specific torquing
instructions, failure to torque properly will cause
component damage.

8. Place the failed PC Board in the ESD protective
bag and seal for return shipping.

9. Replace the power supply cover.

10. Remove the grounding wrist strap from your wrist
and from the electrical ground connection before
reconnecting primary power to the equipment.

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.

Do not operate the equipment or test equipment
under power while wearing the grounding wrist
strap.

Observe torquing requirements where given. Fail­ure to torque properly will cause component dam­age.

Manual 0-2972 5-1 REPLACEMENT PROCEDURES

WARNING

Disconnect primary power from the source before
opening or disassembling the power supply.

Before disassembling any part of the Power Supply first
read the procedure for the part to be replaced, then pro­ceed with the disassembly.

5.04 Major External Parts
Replacement

B. Tube Handle Replacement

1. Remove the cover per Subsection 5.04-A.

Refer to Section 6.03 for Major External Replacement Parts
and overall detailed drawing.

WARNING

Disconnect primary power from the source before
opening or disassembling the power supply.

A. Cover Removal and Replacement

1. Remove the upper screws securing the cover to the
unit then loosen the lower screws securing the cover
to the base.

Upper
screws

Lower
screws

2. Remove the four bolts and star washers securing
the tube handles to the base of the unit.

3. Move the input power cable, torch leads and work
cable inside the handle, then lift the base of the
unit away from the Tube Handle.

4. With a rubber mallet, separate the two handle ends
as shown below.

5. Install the replacement Tube Handle by reversing
the above steps.

Lower
screws

Ground wire

Art # A-03939

2. Carefully lift the cover up and away from the unit
to gain access to the ground wire connection on the
inside of the cover (left side near front).

3. Remove the nut and washer from the ground stud
on the inside of the cover.

4. Install the replacement cover by reversing the above
steps.

Art # A-02847

5.05 Front Panel Parts Replacement

Refer to Section 6.04 for Front Panel Replacement Parts
and overall detailed drawing.

WARNING

Disconnect primary power from the source before
opening or disassembling the power supply.

A. CURRENT (A) Knob Replacement

1. Turn the adjustment fully clockwise and note the
location of the pointer on the knob.

2. Loosen the screw securing the Current Knob to the
potentiometer shaft and remove the Current Knob.

3. Place the replacement Current Knob on the potenti­ometer shaft with the pointer in the same position
as noted in step 1.

4. Tighten the screw to secure the knob to the potenti­ometer shaft.

REPLACEMENT PROCEDURES 5-2 Manual 0-2972

B. ON/OFF Switch (SW1) Replacement

D. POT/LED PC Board Replacement

1. Remove the power supply cover per Subsection

5.04-A.

2. Disconnect the wires on the rear of the Switch, not-
ing the location and orientation of each wire as
shown below:

Top clip

Wire #21

Wire #24

Wire #22

Wire #23

Art # A-02774

3. Squeeze together the clips on the rear of the Switch,
then remove the Switch through the Front Panel.

4. Install the replacement Switch by reversing the
above steps.

C. RUN / RAPID AUTO RESTART / SET

Switch (SW2) Replacement

1. Remove the cover per Subsection 5.04-A.

2. Disconnect the wires on the rear of the Switch, not-
ing the location and orientation of each wire as
shown below:

Follow the antistatic procedures in Subsection 5.02.

1. Remove the cover per Subsection 5.04-A.

2. Remove Current Knob per procedures in Subsec­tion 5.05-A.

3. Disconnect J Connector from POT/LED PC Board.

4. Remove PC Board from standoffs.

5. Install the replacement POT/LED PC Board by re­versing the above steps.

E. Work Cable Replacement

1. Remove the cover per Subsection 5.04-A.

2. Disconnect the Work Cable from the WORK termi­nal on the Main Power PC Board, located on the left
side of the unit.

3. Squeeze the top and bottom of the Work Cable Strain
Relief and remove from the Front Panel.

4. Remove Work Cable from the unit.

5. Install the replacement Work Cable by reversing
the above steps.

5.06 Left Side Internal Parts
Replacement

Refer to Subsection 6.05 Left Side Internal Replacement
Parts.

Top clip

Wire #46

Wire #26

Wire #25

Art # A-03906

3. Squeeze together the clips on the rear of the Switch,
then remove the switch through the Front Panel.

4. Install the replacement switch by reversing the
above steps.

5. Reinstall the power supply cover.

WARNING

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.

2. Locate the Fuse near the top edge of the Main Power
PC Board and remove the Fuse.

3. Install replacement fuse.

4. Reinstall the power supply cover.

Manual 0-2972 5-3 REPLACEMENT PROCEDURES

B. Main Input Contactor (W1) Replacement

D. Logic PC Board Replacement

1. Remove the cover per Subsection 5.04-A.

2. Label and disconnect all wiring leading to the con­tactor.

3. Remove the hardware securing the Input Contac­tor to the base of the power supply.

4. Fasten the replacement Contactor in place with the
label positioned as shown in the illustrations.

5. Connect the wiring as shown below.

NOTE

It is important that wires are installed correctly, as
shown, to prevent damage to the unit.

For 208/230-Volt Power Supplies:

White Input
Cable (L1)

Blue
Wire #3

Blue
Wire #4

Blue
Wire #12

Black
Cable #2

T1

T2

Follow the antistatic procedures provided in Subsection

5.02.

1. Remove the cover per Subsection 5.04-A.

2. Unlock the two tabs on the card guides protruding
from the Main PC Board. Push in the silver part of
the tab until the black part pops out on the other
side.

3. Gently pull the Logic PC Board from the Main Power
PC Board.

4. Install the replacement Logic PC Board by revers­ing the above steps. Note the following:

a. The pins on the Logic Board must be fully

seated in the J1 connector on the Main PC
Board. Ensure that the tabs on the card guides
close properly.

b. The small pin inside the tab on the card guide

must slide through the hole in the PC Board to
ensure the PC Board is properly secured.

5. Reinstall the power supply cover.

E. IGBT Circuit Board or Output Diode

Replacement

Black Input
Cable (L2)

A-02849

Blue
Wire #11

Label

Black
Cable #1

For 400-Volt and 460-Volt Power Supplies:

To E2

To E3

Connections to

Main PCB

To E1

T1 T2 T3

L1 L2 L3

Input Side

L3

L2

L1

#3

#12

#4

Main Contactor

Follow the antistatic procedures in Subsection 5.02.

WARNINGS

Follow the electrostatic discharge instructions in­cluded with the component to prevent damage to
the component.

Thermal pads and the large flat surface on the back
of diodes and IGBTs must be kept clean. Thermal
pads must not be allowed to pick up any foreign
material. A very clean installation between the
module and heatsink is essential for proper opera­tion.

Label

1. Remove cover per Subsection 5.04-A.

2. Turn the Power Supply onto its side.

3. For IGBTs, disconnect the small jumpers from their
connections to the Main PC Board. Label and care­fully remove all other wire connections from the
Board being replaced.

#11

6. Reinstall cover.

REPLACEMENT PROCEDURES 5-4 Manual 0-2972

A-03176

4. Remove screw securing Board in place. Remove
board and its screw from the power supply.

5. Use isopropyl alcohol and a clean rag to clean the
heatsink. Remove all residue of the original ther­mal pad. Do not scratch or abrade the surface.

6. The thermal pad, provided with the replacement
part, is a thin metal pad. Remove and discard any
loose protective paper coverings from the pad.

CAUTION

Protective coverings must be removed from the ther­mal pad. Installing a thermal pad with protective
coverings in place will cause equipment damage or
failure.

7. Apply the round thermal pad to the heatsink with
a small piece of light-duty tape. Tape must cover
no more than 1/8” (3 mm) of the edge of the ther­mal pad. Use the screw hole in the heatsink as a
guide to position the pad.

8. For IGBTs, remove the small jumpers from the com­ponent being replaced. Transfer the jumpers to
the replacement component.

9. Clean the large flat surface on the back of the re­placement component with isopropyl alcohol.

10. Install modules as follows:

a. Put the replacement module in position, and

secure with the screw removed previously. En­sure that the washer is under the head of the
screw.

11. Reconnect the wiring per the applicable chart.

CutMaster 5 1

IGBT Wiring Conne ctions

From IGBT

Terminals

To Main PCB

Terminals
E28, E 29 E13
E32, E 33 E15

E30,E31 E35

J18 J20
J19 J21

Output Diode Wiring Connec t i ons

From Out put

Diode
E38, E 39
E42, E 43
E36, E 37
E40, E 41

To Main PCB

E21
E19
E18
E20

11. Stand the Power Supply upright. Re-connect pri­mary input power, and test the unit per directions
in Section 4.10-G.

12. When all tests are completed, re-install the power
supply cover.

Heatsink

Round Thermal Pad

Diode
or IGBT

Tape

WasherScrew

Main PCB

Art # A-03907

b. Torque the screw to 17 inch-pounds (1.9 Nm).

CAUTION

Failure to torque properly will cause component
damage.

Manual 0-2972 5-5 REPLACEMENT PROCEDURES

F. Input Diode Replacement

WARNINGS

Follow the electrostatic discharge instructions in­cluded with the component to prevent damage to
the component.

Thermal pads and the large flat surface on the back
of diodes must be kept clean. Thermal pads must not
be allowed to pick up any foreign material. A very
clean installation between the module and mount­ing plate is essential for proper operation.

Input Diode

Mounting Plate

Thermal Pad

Input Diode

1. Remove cover per Subsection 5.04-A.

2. Label and disconnect wires from the Input Diode.

3. Remove screws securing Board in place. Remove
board and its screws from the power supply.

4. Use isopropyl alcohol and a clean rag to clean the
mounting plate. Remove all residue of the original
thermal pad. Do not scratch or abrade the surface.

5. Clean the large flat surface on the back of the re­placement component with isopropyl alcohol.

6. The thermal pad, provided with the replacement
part, is a thin metal pad. Remove and discard any
loose protective paper coverings from the pad.

CAUTION

Protective coverings must be removed from the ther­mal pad. Installing a thermal pad with protective
coverings in place will cause equipment damage or
failure.

6. Apply the thermal pad to the diode. Use the screw
hole and slot in the mounting plate as a guide to
position the pad.

E6

E8

E5

E13

E18

E16
E14

Art # A-03908

9. Reconnect the wiring per the chart.

CutMa ste r 51 Input Diode W i ring Conne ctions

208/230V

Power Supplies

400V, 460V

Power Supplies

E5 E1

E5, E13, E18 E2

E13 E2
E18 E3

E6, E8 E11 E6, E8 E11

E14, E 16 E 12 E14, E 16 E 12

10. Re-connect primary input power, and test the unit
per directions in Section 4.10-G.

11. When all tests are completed, re-install the power
supply cover.

7. Install module as follows:

a. Put the replacement module in position, and

secure with the replacement screws. Ensure that
the washers are under the heads of the screws.

b. Torque the screws to 35 inch-pounds (3.95Nm).

CAUTION

Failure to torque properly will cause component
damage.

REPLACEMENT PROCEDURES 5-6 Manual 0-2972

G. Main PC Board Replacement

H. EMI Filter Replacement (CE Units Only)

Follow the antistatic procedures provided in Subsection

5.02.

1. Remove cover per Subsection 5.04-A.

2. Remove the Logic PC Board per Subsection 5.06-D.

3. Remove the POT/LED PC Board per Subsection

5.05-D.

4. Disconnect all wire and cable connections to the
Main PC Board, including the connections from
the three smaller PC Boards. Refer to the Main PC
Board Wiring Diagrams in the Appendix pages if
necessary.

5. Remove the two long Transformer screws securing
the Auxiliary Transformer to the Center Chassis.

6. Remove the other screws securing the PC Board to
the Center Chassis.

7. Carefully remove the original PC Board.

8. Install the replacement PC Board by reversing steps
above. It may be easier to install the PC Board if the
Power Supply is turned on its right side first. Torque
the screws to 17 inch-pounds (1.9 Nm).

Refer to Subsection 6.05 for parts list and overall detailed
drawing.

WARNING

Disconnect input power at the source and bleed down
the system before attempting these procedures.

1. Label the input power cable connections and the
cable connections to the main input contactor.

2. Disconnect all wire and cable connections to the
EMI Filter.

3. Remove the hardware securing the EMI Filter. This
hardware passes upward through the base of the
power supply.

4. Put the replacement EMI Filter in position and se­cure it with the hardware removed in Step 3.

5. Connect the input power cables and the cable con­nections to the main input contactor.

6. Test the Power Supply for proper operation.

Auxiliary Transformer

1

9

Art # A-03909

2

4

Attachment

IGBT

6

5

Screws

10

Output

Diode

3

7

8

12

11

9. Reconnect all wiring. Refer to the Appendix pages
in this manual for wiring details.

Manual 0-2972 5-7 REPLACEMENT PROCEDURES

5.07 Rear Panel Parts Replacement

Refer to Subsection 6.07 for parts list and overall detailed
drawing.

WARNING

4. Note the correct assembly of the filter/spool then
remove the filter from the spool. Either clean or
replace the filter element.

5. The filter element and spool, with the baffle ring in
place (teeth facing downward) can be screwed back
into the Regulator body by compressing the spring
on the spool. Tighten firmly by hand.

Disconnect input power at the source and bleed down
the system before attempting these procedures.

A. Filter/Regulator Assembly Replacement

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 the nut securing the Filter/Regulator As­sembly to the Regulator Mounting Bracket. Remove
the Filter-Regulator Assembly from the Mounting
Bracket.

5. Install the replacement Filter/Regulator Assembly
by reversing the steps above. When connecting the
gas tube to the Adapter Fitting, simply insert the
hose into the fitting until fully seated and it will
automatically lock.

6. Reinstall the bowl.

7. Slowly apply air pressure to the assembly, check­ing for leaks.

D. Optional Single-Stage Filter Element

Replacement

NOTES

The Power Supply shuts down automatically when
the Filter Element becomes completely saturated.
The Filter Element can be removed from its hous­ing, dried, and reused. Allow 24 hours for Ele­ment to dry.

1. Remove power from power supply.

2. Disconnect gas supply hose.

3. Turn the Cover counter-clockwise and remove it
from the Filter Housing. The Filter Element is lo­cated inside the Housing.

4. Remove the Filter Element from the Housing and
set Element aside to dry.

B. Filter/Regulator Bracket Replacement

1. Remove the four bolts securing the Regulator
Bracket to the Rear Panel.

2. Remove the nut securing the Filter/Regulator As­sembly to the Regulator Bracket. Remove the
Bracket from the Filter-Regulator Assembly.

3. Install the replacement Bracket by reversing the
above steps.

C. Standard Filter Element Replacement

1. Remove power from the power supply; turn off the
gas supply.

2. Unscrew the bowl on the bottom of the Regulator/
Filter Assembly. The filter element will be visible
and still attached to the main body of the Regula­tor/Filter Assembly.

3. Grasp the filter element and unscrew it from the
Regulator/Filter body. The filter element will
come off with a spool and some additional pieces.

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

(Cat. No. 9-7743)

Cover

Barbed

Fitting

Assembled Filter

Art # A-02476

5. Wipe inside of housing clean, then insert the re­placement Filter Element open side first, as shown.

REPLACEMENT PROCEDURES 5-8 Manual 0-2972

6. Replace Housing on Cover.

F. Input Power Cable Replacement

7. Attach gas supply hose.

NOTE

If unit leaks between housing and cover, inspect the
O-Ring for cuts or other damage.

E. Optional Two-Stage Filter Element

Replacement

NOTE

The Two-Stage Air Filter has two Filter Elements.
When the Filter Elements become dirty the Power
Supply will continue to operate but cut quality may
become unacceptable.

1. Remove power from power supply.

WARNING

Always turn off the air supply and bleed the system
before disassembling the Filter Assembly as injury
could result.

1. Remove the cover per Subsection 5.04-A.

2. Label and disconnect the wires from the Main In­put Contactor.

3. Remove the hardware securing the input power
ground wire to the ground stud on the base of the
unit.

4. Unthread the retaining nut on the Input Cable
Strain Relief on the inside of the Rear Panel. Re­move the Input Power Cable from the unit.

5. Install the replacement Input Power Cable by re­versing the above steps. The input cable ground
wire requires a ring terminal. Refer to the follow­ing illustrations for wire connections.

For 208/230-Volt Power Supplies:

White Input
Cable (L1)

Blue
Wire #3

Blue
Wire #12

Black
Cable #2

T1

2. Loosen the two bolts on the top of the Filter Assem­bly enough to allow the Filter Elements to move
freely.

First & Second
Stage
Cartridges
(as marked)

Art # A-02942

3. Slide out the old Filter Elements.

4. Slide the replacement Filter Elements into the Filter
Assembly, with the original orientation.

5. Hand tighten the two bolts evenly, then torque each
bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm).

6. Slowly apply air pressure to the assembly, check­ing for leaks.

Blue
Wire #4

Black Input
Cable (L2)

A-02849

Blue
Wire #11

Label

Black
Cable #1

For 400-Volt and 460-Volt Power Supplies:

To E2

To E3

Connections to

Main PCB

T1 T2 T3

L1 L2 L3

Input Side

L3

L2

L1

#3

#12

#11

#4

Main Contactor

T2

To E 1

Label

A-03176

Manual 0-2972 5-9 REPLACEMENT PROCEDURES

5.08 Right Side Internal Parts
Replacement

Refer to Section 6.07 Right Side Internal Parts List and
overall detailed drawing.

6. Install the replacement Pressure Switch/Solenoid
Assembly by reversing the above steps. Once in­stalled, the Solenoid Assembly should fit securely
under the Fan Shroud and should not be move­able.

7. Reinstall the power supply cover.

WARNING

Disconnect primary power from the source before
opening or disassembling the power supply.

A. Pressure Switch/Solenoid Assembly (PS1/

SOL1) Replacement

The Pressure Switch and Solenoid Valve are one Assembly.

1. Remove the cover per Subsection 5.04-A.

2. Disconnect:

a. Wires #9 and #10 from the Pressure Switch As-

sembly.

b. Wires #7 and #8 from the Solenoid Assembly.

3. Use a tool (screwdriver, etc.) to push the clip on the
front of the Fan Shroud to the left. Release the Sole­noid Assembly. Dislodge the Solenoid from under­neath the clip on the top of the Fan Shroud.

B. Fan (M1) Replacement

1. Remove the cover per Subsection 5.04-A.

2. Remove the two screws securing the Fan to the Fan
Shroud and let the Fan drop down.

3. Turn the Fan slightly and slide the Fan out, left side
first.

4. Carefully remove the two wiring connectors from
the terminals on the Fan Assembly.

5. Install the replacement Fan Assembly as follows:

a. Position Fan with the label facing inward and

the Fan terminals facing bottom right.

b. Connect the two wire connectors to the two Fan

terminals.

c. Slide the right end of the Fan in through the

Shroud first, then the left.

NOTE

Only two screws are needed to attach the Fan to the
Shroud and 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.

Dislodge Solenoid

3

2

Push Clip

to the left to

release Solenoid

Assembly

Art # A-03705

Assembly

1

Heatsink
Shroud

4. Release the hose from the Adapter Fitting on the
left 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.

5. Release the hose from the Adapter Fitting on the
right side of the Pressure Switch.

d. Line up the Fan holes with the screw holes in

the Fan Shroud then attach the Fan by install­ing two screws in opposite corners.

REPLACEMENT PROCEDURES 5-10 Manual 0-2972

C. Pilot PC Board Replacement

The Pilot PC Board mounts to the Power Supply center
chassis. Refer to Pilot Board Layout in theAppendix.

1. Remove the cover per Subsection 5.04-A.

2. Label and disconnect wires from Pilot PC Board
terminals E58 and E62. Disconnect the wire har­ness from receptacle J28.

3. Remove the hardware securing the Pilot PC Board
to the power supply center chassis. Remove the
Pilot PC Board.

4. Position the replacement Pilot PC Board against
the standoffs fastened to the center chassis. Note
that the Pilot PC Board mounts with its printed text
upside down. Fasten the Pilot Board to the stand­offs with the hardware removed previously. Torque
the hardware to 18 in-lbs (2.04 Nm).

5. Reconnect the wires to the Pilot PC Board. Wire #58
connects to terminal E58; wire #62 connects to ter­minal E62. Ensure that the wire harness connector
is fully seated in receptacle J28.

6. Reinstall the power supply cover.

D. Main Transformer (T5) Replacement

The Main Transformer is located behind the Fan Shroud.
For access to the Main Transformer, remove the Solenoid/
Pressure Switch Assembly and the Fan and Fan Shroud.

1. Remove the cover per Subsection 5.04-A.

2. Release the tabs on the side and top of the Fan
Shroud securing the Solenoid/Pressure Switch
Assembly in position, enabling the Assembly to
move freely.

3. Remove the gas hose from the Solenoid Fitting by
pressing on the locking ring while pulling on the
hose.

4. Remove Fan per Subsection 5.08-B. The Fan Shroud
cannot be tilted up until the Fan wires are discon­nected from the Fan. Removing the Fan also pro­vides better access to the Main Transformer for re­installation.

5. Remove the nuts securing the Fan Shroud to the
Center Chassis.

6. Locate the two tabs below the Main PC Board se­curing the Fan Shroud to the Center Chassis. Use
a screwdriver to push these tabs down to release
the Shroud.

7. Label and disconnect cables at the following points
on the Main Power PC Board. Refer to the Appen­dix pages for wiring details.

• Primary to Main PCB Terminals E4 and E35

• Secondary to Main PCB Terminals E8 and E9

8. Tilt the Fan Shroud up from the bottom to expose
the Main Transformer and disconnect wire con­nector on the Coil Winding.

9. Remove the Transformer from the unit, carefully
guiding all the connected cables and wires as you
do so.

10. Turn unit onto its left side.

11. Position the replacement Transformer as follows:

a. with the PC Board facing out from the unit;

b. the cables oriented to the right side;

c. the four Transformer Rubber Feet well seated in

the four holes in the Center Chassis.

12. Feed the Transformer wires and cables as follows:

a. White Transformer Cable - feed through bottom

hole in Center Chassis.

b. Black Transformer Cable - feed through hole in

Top of Fan Shroud, then through hole in Center
Chassis below Pilot PC Board.

c. Blue Fan Wires - feed through same hole in Fan

Shroud as Black Cable, then through hole at
right side of Center Chassis.

13. Secure the Main Transformer in position by lock­ing the two tabs on the bottom of the Shroud into
the Center Chassis. Start with the left side first,
lock it in position, then repeat with the right side.

14. Install the two nuts and washers securing the
Shroud to the Center Chassis.

15. Connect wire connector to the Coil Winding on the
Main Transformer.

16. Reinstall the Pressure Switch/Solenoid Assembly.

17. Reinstall the Fan per Subsection 5.08-B and recon­nect the wiring.

18. Reconnect cables to the following points on the
Main Power PCB. Refer to the Appendix pages for
wiring details.

• Primary to Main PCB Terminals E4 and E35

• Secondary to Main PCB Terminals E8 and E9

Manual 0-2972 5-11 REPLACEMENT PROCEDURES

19. Re-install cover per Subsection 5.04-A.

E. Output Inductor Assembly (L1) Replacement

1. Remove the cover per Subsection 5.04-A.

2. Disconnect the two wires connected to terminals
E5 and E10 located on the right side of the Main
Power PC Board. Pull through the bottom hole in
the Center Chassis.

3. Disconnect the wires connected to J23 on the Main
PC Board, removing tie wraps as necessary.

4. Remove the front mounting screw securing the
Output Inductor Assembly to the unit base.

5. Remove grommet from Fan Shroud for better access
to the Output Inductor Assembly rear mounting
stud.

6. Pass a magnetic socket with a long extension
through the hole in the Fan Shroud directly above
the Output Inductor Assembly rear stud. Remove
the nut. Use tape on the socket if the socket is not
magnetic.

7. Install the replacement Output Inductor Assembly
by reversing the above steps. Note the following:

a. The Output Inductor wires should be oriented

towards the front of the unit.

This concludes the replacement procedures.

REPLACEMENT PROCEDURES 5-12 Manual 0-2972

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 Replacement Parts

Section 6.06 Right Side Internal Replacement Parts

Section 6.07 Rear Panel 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 authori­zation will not be accepted.

6.02 Ordering 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 autho­rized distributor.

Manual 0-2972 6-1 PARTS LISTS

6.03 Major External Replacement Parts

Item # Qty Description Catalog #

1 1 Cover with labels 9-7999
2 1 Tube, roll handle 9-8320

Hardware:

A 8 Screw, 10-32 x 1/2 PPH Swageform See Note 1

B 4 Washer, 1/4 External Star See Note 1

C 4 Screw, 1/4 - 20 x 3/4" Hex See Note 1

1

A

B,C

2

2

Art # A-02819

NOTES

1. May be purchased locally.

2. Illustration may vary slightly from unit.

PARTS LISTS 6-2 Manual 0-2972

6.04 Front Panel Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Knob, Fluted, Skirted, 0.250 I.D. 9-8527
2 1 On/Off Rocker Switch SW1 8-3258
3 1 Run/Rapid Auto Restart / Set Switch SW2 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

1

4

3

2

Art # A-02850

5

NOTE

Illustration may vary slightly from unit.

Manual 0-2972 6-3 PARTS LISTS

6.05 Left Side Internal Replacement Parts

Item # Qty Description Ref Catalog #

1 Fuse F1

1 1/2A, 250V (For 208/230-Volt units) 9-8110
1 1/2A, 600V (For 400-Volt and 460-Volt units) 9-8583

Main Input Contactor W1

2A 1 For 208/230-Volt Units 9-8522

2B 1 For 400-Volt and 460-Volt Units 9-8554

3 PCB Kit, Input Diode 9-7088

1 Input Diode
1 Thermal Pad
2 External star washer
2 Screw, 8-32 x 1/2", PPH

4 1 PCB Assembly, Logic Board, Non-mechanized units 9-7996
4 1 PCB Assembly, Logic Board, Mechanized units 9-9439

5 1 PCB Kit, IGBT Circuit 9-8540

1 Round Thermal pad

6 1 PCB Kit, Output Diode 9-8539

1 Round Thermal pad

7 PCB Kit, Main Power

1 For 208/230-Volt Units 9-7993
1 For 400-Volt Units 9-7994
1 For 460-Volt Units 9-7995

8 1 EMI Filter Assembly (CE Units only) 9-8561

Hardware:

A 4 Hex nut See Note

B 2 Screw, 8-32 x 3/4, PPH, with external star washer See Note
C 3 Washer, 0.125 ID, zinc See Note
D 1 Screw, 8-32 x 1", PPH, with external star washer See Note

E 10 Screw, 6-32 x 3/8, PPH, with external star washer See Note

NOTE

May be purchased locally.

PARTS LISTS 6-4 Manual 0-2972

Center Chassis

7

E

1

5

B,C

4

6

B,C

Input Diode

Mounting Plate

(part of Center Chassis)

3

8

A

OR

2A

2B

Art # A-03904

NOTE

Illustration may vary slightly from unit.

Manual 0-2972 6-5 PARTS LISTS

6.06 Right Side Internal Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Assembly, Pressure Switch/Solenoid SOL1, PS1 9-8329

2 1 Assembly, Pilot PCB 9-8337

3 Fan, 220V, 115 CFM M1 9-7687

4 1 Assembly, Main Transformer T5 9-8544

5 1 Assembly, Output Inductor L1 9-8560

Hardware:

A 5 10-32 x 1/2 pph screw See Note

B 1 #10 External star washer See Note
C 1 1/4-20 nut, brass See Note
D 3 10-32 Kepnut w/ star washer See Note

E 4 6-32 x 3/8" pph screw See Note

F 2 6-32 x 3-1/2" pph screw See Note
G 1 1/4" External star washer See Note

H 1 1/4-20 X 1" hex bolt, brass See Note

NOTE

May be purchased locally.

PARTS LISTS 6-6 Manual 0-2972

2

E

A

4

1

3

A, B

Art # A-03905

NOTE

Illustration may vary slightly from unit.

Heatsink

D

A

5

Manual 0-2972 6-7 PARTS LISTS

6.07 Rear Panel Replacement Parts

Item # Qty Description Catalog #

1 1 Assembly, Filter/Regulator 9-7514

2 1 Regulator/Filter Replacement Element 9-4414

3 1 Regulator Mounting Bracket 9-7589

4 1 Input Power Cable

For 208/230-Volt Units 8-4384
For 400-Volt Units (non-CE) 9-8562
For 400-Volt CE Units 9-8553

For 460-Volt Units 9-8593
5 1 Mounting Nut 9-5804
6 1 Pressure Gauge 9-1045

Hardware:

A 2 10-32 x 1/2 PPH Screw See Note 1

B 4 10-32 x 1-1/8" PPH Screw See Note 1

5

3

1

NOTES

1. May be purchased locally.

6

4

2

Art # A-03005

2. Illustration may vary slightly from unit.

PARTS LISTS 6-8 Manual 0-2972

6.08 Options and Accessories

Qty Description Catalog #

1 Single-Stage Filter Kit (Includes Filter And Hose) 7-7507
1 Replacement Filter Body 9-7740
1 Replacement Filter Element 9-7741
1 Replacement Filter Hose (Not Shown) 9-7742

1 Two-Stage Air Line Filter Kit (Includes Hose & Mounting Screws) 7-7500
1 Bracket, Filter Mounting (Not Shown) 9-7535
1 Two-Stage Air Filter Assembly 9-7527
1 Replacement First Stage Cartridge 9-1021
1 Replacement Second Stage Cartridge 9-1022
1 Wheel Kit 9-8510

Not shown:

1 Extended Work Cable - 50 ft (15.2 m) 9-8529
1 Hand Pendant Control With 25 Ft (7.6 m) Cable 7-3114
1 Hand Pendant Control Cable Extension - 25 Ft (7.6 m) 7-7744
1 Multi-Purpose Cart 7-8888

Single-Stage

Filter Kit

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

(Cat. No. 9-7743)

Cover

Barbed

Fitting

Wheel Kit, Installed

Assembled Filter

Art # A-02476

Two-Stage

Filter Kit

First & Second
Stage
Cartridges
(as marked)

Art # A-02942

Manual 0-2972 6-9 PARTS LISTS

A-02958

PATENT INFORMATION

The following parts are licensed under U.S. Patent No(s). 5120930 and 5132512

Catalog Number Description

9-8235 Shield Cap, Drag 50-60A
9-8236 Sheild Cap, Drag 70-100A
9-8237 Shield Cup, Body
9-8238 Shield Cap, Machine 50-60A
9-8239 Shield Cap, Machine 70-100A
9-8244 Shield Cap, Drag 40A
9-8245 Shield Cap, Machine 40A

PARTS LISTS 6-10 Manual 0-2972

APPENDIX 1: INPUT WIRING REQUIREMENTS

t

CutMaster 51 Power Supply Input Wi ri ng Requi re m ents

Input Power Input Current Input Suggested Sizes (S ee Not es )

Voltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph

(Volts) (Hz.) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph 3-Ph 1-Ph 3-Ph

208609 39601010
230609 37601010
40050 8 11151212
400 60 8.5 12 15 12 12
460 60 14 17.5 25 12 12
46060 8 10151212

Line Vol t ages with S ugges ted Circuit Prot ec tion and W i re Si zes

Bas ed on Nat ional E l ectric Code and Canadian Electric Code

CE CutM aster 51 Input Wiring Specifications

Inpu

Voltage Freque ncy 3-Ph 3-Ph Fuse (Amps)

(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph

CE CutM aster 51 400 50 7.9 11.5 15 4

Line Vol t ages with S ugges ted Circuit Prot ec tion and W i re Si zes

Bas ed on Nat ional E l ectric Code and Canadian Electric Code

Pow er Input Current Input

Fuse (Am p s) Wire (AW G) Wire (Canada )

Sugge sted S i z es (See Notes)

Wire (mm

2

)

NOTES

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 0-2972 A-1 APPENDIX

APPENDIX 2: SEQUENCE OF OPERATION (BLOCK

DIAGRAM)

ACTION:

Close external

disconnect switch.

RESULT:

Power to system.

Connect work cable to workpiece.

Set output amperage.

System is ready

for operation.

ON / OFF switch to ON

AC indicator ON.

GAS indicator ON

for power supply operation.

ACTION:

RESULT:

ACTION:

RESULT:

Fan(s) ON.

when input

pressure is adequate

Power circuit ready.

ACTION:

RUN /

Rapid Auto Restart /

SET switch

to SET

RESULT:

Gas flows to set pressure.

Torch moved away from work (while

ACTION:

RUN /

Rapid Auto Restart / SET

switch to RUN

(for most applications)

or to

Rapid Auto Restart

(for gouging, trimming,

or expanded metal

applications)

RESULT:

Gas flow stops.

ACTION:

still activated).

RESULT:

ACTION:

Protect eyes and activate torch.

RESULT:

Gas flows briefly, then stops.

Gas restarts.

DC indicator ON

Pilot arc established.

ACTION:

Release torch trigger.

RESULT:

Main arc stops.

Gas flow stops after post - flow.

PILOT ARC

ACTION:

ON / OFF switch

to OFF

RESULT:

All indicators off.

Power supply fan(s) shuts off.

Main arc stops.

Pilot arc automatically

restarts.

ACTION:

Torch moved within

transfer distance of workpiece.

RESULT:

Main arc transfers.

Pilot arc off.

ACTION:

Unplug input

power cord or

open external

disconnect.

RESULT:

No power to system.

Art #A-03706

APPENDIX A-2 Manual 0-2972

This Page Left Blank

Manual 0-2972 A-3 APPENDIX

APPENDIX 3: LOGIC PC BOARD LAYOUT

P1-1 to P1-36

P1-7

TP6

TP10

TP9

TP8

TP7

TP4

TP3

TP1

TP2

TP5

D8

APPENDIX A-4 Manual 0-2972

Art # A-03883

Logic Board Signals

P1-1 +12vdc from Main PCB
P1-2 +12vdc from Main PCB
P1-3 Ground
P1-4 Ground
P1-5 Logic Low - W1 on Signal
P1-6 Ground
P1-7 RUN / RAPID AUTO RESTART / SET Signal
Logic Low for SET
P1-8 Logic Low = Pressure good signal
P1-9 Overtemp Signal (Logic Low)
P1-10 Ground
P1-11 Ground
P1-12 Ground
P1-13 28VAC
P1-14 Logic Low = Gas on Signal to Main PCB
P1-15 Logic Low = CSR Signal from Main PCB
P1-16 Ground
P1-17 Logic Low = DC OK Signal to Main PCB
P1-18 Logic Low = OVERTEMP Signal to Main PCB
P1-19 Logic Low = AC OK Signal to Main PCB
P1-20 Return for Torch Switch
P1-21 Logic Low = Torch Switch Signal
P1-22 +12 vdc
P1-23 To Current Control Pot
P1-24 Current Control
P1-25 Current Control Return

P1-26 Gate Drive B Return
P1-27 Gate Drive B Signal
P1-28 Gate Drive A Return
P1-29 Gate Drive A Signal
P1-30 (-) Output Signal
P1-31 Current Sense Signal
P1-32 Current Sense Signal
P1-33 Current Sense Return
P1-34 Current Sense Return
P1-35 ISense
P1-36 Tip

TP1 Logic Ground
TP2 DC OK Signal
TP3 CSR Signal
TP4 PWM Fault Shutdown
TP5 Demand Signal
TP6 Overtemp Fault
TP7 (-) Output Signal
TP8 Gate Drive A Signal
TP9 Gate Drive A Return
TP10 Gate Drive B Signal

INDICATOR LED:
D8 Inverter On

Manual 0-2972 A-5 APPENDIX

APPENDIX 4: MAIN POWER PC BOARD LAYOUT

E1

E2

E3

E12

E35

E30

TP14

E22

E11

E4

E31

J18

E14

J8

LT 1

Fuse

(F1)

IGBT

J26

TP10

TP18

TP2

J5

J4

TP1

Output

Diode

J2

J23

J3

J1

E18

E23

E26

E5

E43

E36

E41

E6

TP5

J22

J9

E25

E24

E42

E37

E28

E40

E28

E29

E15

E13

E33

E32

J19

TP13

J21

Main Power PC Board Signals

J1-1 +12vdc to Logic PCB
J1-2 +12vdc to Logic PCB
J1-3 Ground
J1-4 Ground
J1-5 Logic Low = - W1 on Signal
J1-6 Ground
J1-7 RUN / RAPID AUTO RESTART /SET Signal Logic
Low for SET
J1-8 Logic Low = PS1 Closed=Pressure OK

to Logic PCB
J1-9 Logic Low = TS1 (or TS2) Closed = Overtemp
J1-10 Ground
J1-11 Ground
J1-12 Ground
J1-13 28VAC A
J1-14 Logic Low = Gas on Signal from Logic PCB

E17

E10

Art #A-03751

E16

J20

E7

E34

E19

E8

E21

E39

E9

E38

E27

E20

J1-15 Logic Low = CSR Signal to Logic PCB
J1-16 Ground Signal
J1-17 Logic Low = DC OK Signal from Logic PCB
J1-18 Logic Low = OVERTEMP signal from Logic PCB
J1-19 Logic Low = AC OK signal from Logic PCB
J1-20 Return
J1-21 Logic Low = torch switch signal to Logic PCB
J1-22 +12 vdc to Logic PCB
J1-23 Pot High
J1-24 Pot Wiper
J1-25 Pot Low
J1-26 Gate Drive B Return from Logic PCB
J1-27 Gate Drive B from Logic PCB
J1-28 Gate Drive A Return from Logic PCB
J1-29 Gate Drive A from Logic PCB

APPENDIX A-6 Manual 0-2972

J1-30 Negative out
J1-31 Current Sense
J1-32 Current Sense
J1-33 Current Sense Return
J1-34 Current Sense Return
J1-35 I Sense
J1-36 Tip (PIP?)

J2-1 Overtemp Signal from TS1 mounted on Heatsink
J2-2 Overtemp Return
J2-3 Jumpered to J2-4
J2-4 Jumpered to J2-3

J21-1 Gate Drive A Return
J21-2 Gate Drive A

J22-1 Pot High
J22-2 Pot Wiper
J22-3 Pot Low
J22-4 +12V
J22-5 AC Indicator

J22-6 GAS Indicator

J22-7 TEMP Indicator

J3-1 Not used.
J3-2 Not used.
J3-3 28VAC B from Auxiliary Transformer to On/OFF Switch
J3-4 28VAC A from Auxiliary Transformer to ON/OFF Switch
J3-5 28VAC A from ON/OFF Switch to Main PC Board
J3-6 28VAC B from ON/OFF Switch to Main PC Board
J3-7 RUN / RAPID AUTO RESTART / SET Signal Logic Low
Logic Low = SET Mode
J3-8 RUN / RAPID AUTO RESTART / SET Return

J4-1 28VAC A to Gas Solenoid
J4-2 28VAC B to Gas Solenoid
J4-3 Pressure Switch Signal Logic Low
J4-4 Pressure Switch Signal Return Low
J4-5 28VAC Main Contactor W1
J4-6 28VAC to Main Contactor W1
J4-7 +12V
J4-8 Ground from Pilot Board
J4-9 Current Sense to Pilot Board
J4-10 ISense to Pilot Board

J5-1 28VAC A - for test only
J5-2 Ground - for test only
J5-3 28VAC B - for test only

J22-8 DC Indicator

J23-1 Overtemp Signal from TS2 mounted

in Output Inductor

J23-2 Overtemp Return

J26-1 230V to Fan
J26-2 Not Used
J26-3 Not Used
J26-4 230V to Fan

TP1 Logic Ground
TP2 Not Used
TP5 +12vdc
TP10 Current Sense Signal Return
TP18 Current Sense Signal Return

LT1 Power ON Indicator (indicates power

is present on the line side of the Input
Contactor)

J8-1 230VAC from Primary of Aux Transformer Fan Power
J8-2 Not Used
J8-3 Not Used
J8-4 230VAC from Primary of Aux Transformer Fan Power

J9-1 PIP Return
J9-2 PIP
J9-3 Torch Switch
J9-4 Torch Switch Return

J20-1 Gate Drive B Return
J20-2 Gate Drive B

Manual 0-2972 A-7 APPENDIX

APPENDIX 5: PILOT BOARD LAYOUT

E58E62

Pilot PC Board Signals

J28-1 + 12V to Main PC Board Connector J4-7

No Receptacle

OR

J28

E58E62

2 - Pin

Receptacle (J1)

J28

Art # A-03880

J28-2 Ground

J28-3 Logic Low = Rapid Auto Restart OFF

J28-4 Not Used

J28-5 CSR to Main PC Board Connector J4-9

J28-6 Not Used

J28-7 Not Used

J28-8 I Sense to Main PC Board Connector J4-10

NOTES

1. Pilot PC Board mounts to power supply as shown, with text upside down.

2. Pilot PC Board with receptacle J1 may replace PC Board without receptacle J1.

3. Receptacle J1 is used only in automated applications.

APPENDIX A-8 Manual 0-2972

APPENDIX 6: LED/POT PC BOARD LAYOUT

J14

D4

D5

D6

A-03712

Pot/LED PC Board Signals

J14-1 +10 vdc from Logic PC Board (J22-1) Pot High
J14-2 Current Controlto Logic PC Board (J22-2) Pot Wiper
J14-3 Return for Current Control from Logic PC Board (J22-3) Pot Low
J14-4 12vdc (J22-4)
J14-5 Logic Low Signal for AC OK Indicator from Logic PC Board (J22-5)
J14-6 Logic Low Signal for GAS Indicator from Logic PC Board (J22-6)
J14-7 Logic Low Signal for TEMP Indicator from Logic PC Board (J22-7)
J14-8 Logic Low Signal for DC Indicator from Logic PC Board (J22-8)

D4 Front Panel AC Indicator

D5 Front Panel TEMP Indicator

D6 Front Panel GAS Indicator

D7 Front Panel DC Indicator

D7

Manual 0-2972 A-9 APPENDIX

APPENDIX 7: IGBT CIRCUIT PC BOARD LAYOUT

TP14

E28

E31

A-02851

E30

E29

TP13

E32

E33

APPENDIX A-10 Manual 0-2972

APPENDIX 8: INPUT DIODE PC BOARD LAYOUT

E5

E13

E18

E6

E8

E16

E14

Art # A-03882

Manual 0-2972 A-11 APPENDIX

APPENDIX 9: OUTPUT DIODE PC BOARD LAYOUT

E39

E42

A-02853

E43

E38

E36

E37

E41

E40

APPENDIX A-12 Manual 0-2972

This Page Left Blank

Manual 0-2972 A-13 APPENDIX

APPENDIX 10-A: MAIN PC BOARD WIRING (208/230-Volt

units)

E1

E2

E3

To Chassis
Ground

E12

#2

Copper

Strap

Jumper

E11

Solenoid / Pressure Switch

Contactor Harness

LT 1

E22

Fuse

Fan

Harness

To

Transformer

#3

#4

IGBT

To IGBT Heatsink

Te st

Temp Sensor

Connection (Open)

Secondary

Transformer

To Input

Contactor

Jumpers

Output

Diode

To Inductor

Temp Switch

To ON/OFF Switch

and Mode Switch

Logic Board

Connector (J1)

To POT/LED PCB

(or to Optional

Remote Current

Control )*

To Torch
Connector

To Automation
Interface Board
(If Installed)

To Output
Inductor

To Chassis
Ground

To E 2

#1

#2

E6

E8

E5

E13

E18

E16

E14

Input Diode (Attached to
Mounting Plate inside Rear Panel)

To Input Contactor

To Input
Contactor

Work
Lead

To Chassis
Ground

#17

#34

#8

#9

To Main
Transformer
(Secondary)

= Mounting

Screw Location

* If installed in conjuction

with Automation Interface

To To r c h

To Output
Inductor

Art # A-03752

APPENDIX A-14 Manual 0-2972

APPENDIX 10-B: MAIN PC BOARD WIRING (400-Volt and

460-Volt units)

E1

E2

E3

#1

#2

To Chassis
Ground

E12

#44

Solenoid / Pressure Switch

Contactor Harness

LT 1

Fuse

Fan

Harness

E11

To

Transformer

#3

IGBT

#4

To IGBT Heatsink

Test

Connection (Open)

To Input

Contactor

Jumpers

Temp Sensor

Output

Diode

To Inductor

Temp Switch

To ON/OFF Switch

and Mode Switch

Logic Board

Connector (J1)

To POT/LED PCB

(or to Optional

Remote Current

Control )*

To Torch Connector

To Automation
Interface Board
(If Installed)

To Output
Inductor

To Chassis
Ground

To E3

#2

#1

To E1

To E2

#44

E6

E8

E5

E13

E18

Input Diode (Attached to
Mounting Plate inside Rear Panel)

To Input
Contactor

E16

E14

To Input
Contactor

Work
Lead

To Chassis
Ground

#34

#8

* If installed in conjuction

with Automation Interface

#9

To Main Transformer
(Secondary)

#17

To Torch

To Output Inductor

Art # A-03753

Manual 0-2972 A-15 APPENDIX

APPENDIX 11: 28VAC CIRCUIT DIAGRAM

Line Voltage

SOL

1 2 5 6

0.5A Fuse

W1

J4

Auxiliary

Transformer

J81

primary

J8

4

J3

3 4 5 6

ON/OFF Switch

J5

2

3

1

secondary

K2

K5

A-02770

Voltage
Protection
CRT/+12 Regulator

+12vdc

Main Power PC Board

APPENDIX A-16 Manual 0-2972

APPENDIX 12: MAINTENANCE SCHEDULE

This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the
parts listed and those checks need not be performed.

NOTE

The actual frequency of maintenance may need to be adjusted according to the operating environment.

Daily Operational Checks or Every Six Cutting Hours:

1. Check torch consumable parts, replace if damaged or worn.

2. Inspect torch for any cracks or exposed wires, replace if necessary.

3. Check plasma and secondary supply and pressure/flow.

4. Purge plasma gas line to remove any moisture build-up.

5. Inspect input power cable for damage or exposed wires, replace if necessary.

Weekly or Every 30 Cutting Hours:

1. Check fan for proper operation and adequate air flow.

2. Blow or vacuum dust and dirt out of the entire machine.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to
interfere with sensitive electrical components and cause damage to the unit.

Six Months or Every 720 Cutting Hours:

1. Check the in-line air filter(s), clean or replace as required

2. Check cables and hoses for leaks or cracks, replace if necessary.

3. Check all contactor points for severe arcing or pits, replace if necessary.

Manual 0-2972 A-17 APPENDIX

APPENDIX 13: TORCH PIN - OUT DIAGRAMS

A. Hand Torch Pin - Out Diagram

ATC Male Connector

Negative /
Plasma

4 - Green /
Switch

3 - White /
Switch

2- Orange /
PIP

1 - Black /
PIP

4
3

2
1

Pilot

Front View

6

5

8 - Open

7 - Open

8
7

6 - Open

5 - Open

8 - Ground

7 - Open

6 - Open

5 - Open

B. Mechanized (Machine) Torch Pin - Out Diagram

ATC Male Connector

4- Black ­Pendant
Connector

3 - White ­Pendant
Connector

2 - Orange /
PIP

Front View

4
3

2

1

UNSHIELDED MACHINE TORCH

Negative / Plasma

8 - Green ­Pendant
Connector
Ground

8

7

6

5

7 - Green /
Not Used

6 - Open

8 - Ground

7 - Open

6 - Open

ATC Female Receptacle

Front View

8
7

6

5

Pilot

ATC Female Receptacle

8
7

6

5

2
1

Front View

4
3

2
1

Negative /
Plasma

4 - Switch

3 - Switch

4
3

2 - PIP

1 - PIP

A-03701

Negative / Plasma

4 - Switch

3 - Switch

2 - PIP

1 - Black /
PIP

Pilot

Art # A-03799

APPENDIX A-18 Manual 0-2972

5 - White /
Not Used

5 - Open

1 - PIP

Pilot

APPENDIX 14: TORCH CONNECTION DIAGRAMS

A. Hand Torch Connection Diagram

Torch: SL60 / SL100 Hand Torch
Leads: Torch Leads with ATC Connector
Power Supply: with ATC Receptacle

Torch

Head

PIP

Switch

Torch

Switch

Torch
Leads

Black

Orange

Green

White

Negative / Plasma

Pilot

Male

ATC Leads

Connector

ATC Female

Receptacle

1

2

5

6

4

3

8

7

Power
Supply

1

2

5

6

4

3

8

7

To Power Supply

Circuitry

To Power Supply

Circuitry

Negative / Plasma

Pilot

Art # A-03797

B. Mechanized Torch Connection Diagram

Torch: Unshielded Mechanized SL100 Machine Torch
Leads: Leads with ATC Connector and

Remote Pendant Connector

Power Supply: with ATC Female Receptacle

Male

ATC Leads

Connector

Torch

Head

PIP

Switch

Not

Used

Pilot Lead

Torch
Leads

Black

Orange

White

Green

Negative / Plasma Lead

To Remote Control

Remote
Pendant

Connector

Black

White

Green

ATC Female

Receptacle

Power
Supply

1

1

2

2

5

5

6

6

4

4

3

3

8

8

7

7

To Power Supply

Circuitry

To Power Supply

Circuitry

Negative / Plasma

Pilot

Art # A-03798

Manual 0-2972 A-19 APPENDIX

APPENDIX 15: SYSTEM SCHEMATIC (208/230-Volt Units)

A

B

C

D

E

F

208 / 230V
INPUT

M1
FAN1

CURRENT ADJUST:
20 - 40 AMPS

CURRENT
CONTROL/
LED PCB
19X1604

IGBT
HEATSINK
TEMP

INDUCTOR
TEMP

1

ON/OFF SW

MODE SW

RAR OFF

(PILOT PCB) (F6)

LOGIC

ASSY 19X2000

ASSY 19X2283

230V

INV ON
(RED)

(46)

L1

L2

28VAC B
28VAC A

SW1

RUN

SET

SW2

AC

TEMP

GAS

DC

NTC

tt

TS1

TS2

D8

TORCH SWITCH

GATE DRIVE B RTN

GATE DRIVE A RTN

CURRENT SENSE

CURRENT SENSE
CURRENT SENSE RTN
CURRENT SENSE RTN

CHASSIS
GND

(3)

(4)

(6)

(5)

(21)
(22)
(23)
(24)
(25)
(26)

J14

(35)

1

1

(36)

2

2

(37)

3

3

(38)

4

4

(39)

5

5

(40)

6

6

(41)

7

7

(42)

8

8

+12VDC

+12VDC
GND SIGNAL
GND SIGNAL

GND SIGNAL

RUN/SET

PRESS GOOD

OVERTEMP
GND SIGNAL
GND SIGNAL
GND SIGNAL

28VAC A

GAS ON

CSR

GND SIGNAL

DC OK

OVTEMP

AC OK

RTN

+12VDC

POT HIGH

POT WIPER

POT LOW

GATE DRIVE B

GATE DRIVE A

- OUT

ISENSE

W1

(1)

W1

(2)

P8 J8

1
2
3
4

1
2
3
4

1
2
3
4
5
6
7
8

P22P14

1
2
3
4
5
6
7
8

P2

1
2
3
4

P23 J23

121

P1

1
2
3
4

W1

5
6
7
8
9

10

10

11

11

12

12

13

13

14

14

15

15

16

16

17

17

18

18

19

19

20

20

21

21

22

22

23

23

24

24

25

25

26

26

27

27

28

28

29

29

30

30

31

31

32

32

33

33

34

34

35

35

TIP

36

36

2

E14

1
2
3
4

F1 (6/10A 600V)

R95

(0 ohm)

J26P26

1
2
3
4

K3

J3P3

1
2
3
4
5
6
7

TO BIAS SUPPLY

8

INRUSH

FAN

J22

1

POT HIGH

2

POT WIPER

3

POT LOW
+12V

4

AC

5

GAS

6
7

OVERTEMP

8

DC

J2

1
2
3
4

2

J1

1
2
3
4
5

K2
6
7

CONTACTOR ON

8
9

K5

SOLENOID ON

MAIN BOARD
ASSY 19X2001

CHASSIS GND

THRU SCREW TERMINAL

E16E16

K4

K3

E3E3

(FILTERING)

K4

T1

28VAC B 28VAC A

28VAC A
28VAC B

+12V

+18V

+18V

+18V

E28E28

E2E2

E1E1

K4

TO BIAS
SUPPLY

PRESS GOOD

3

E5E5

E13E13

E18E18

COPPER STRAP

GATE DRIVE A RTN

GATE DRIVE B RTN

CSR

DC COMMON

K5

F2, 0.9A,
(RESETABLE)

K2

INPUT DIODE

ASSY 19X2073

GATE DRIVE A

GATE DRIVE B

TORCH SWITCH -

TORCH SWITCH +

CURRENT

SENSE

PIP RTN41

TORCH SW

TORCH SW RTN

28VAC A

28VAC B

ISENSE

CSR

GND

+12V

CSR

J21

J20

Vo

PIP

1
2

1
2

J9

2

3

J5

1
2
3

J4 P4

1
2
3
4
5
6
7
8
9

10

1
2

1
2

E22

1
2

3
4

10

E6E6
E8E8

E14E14
E16E16

E4E4

E9E9

E8E8

E20E20

P9

1
2
3
4
5
6
7
8
9

E17E17

E34E34

E11E11

E12E12

E13E13

E15E15

P21

P20

E35E35

E21E21

E26E26
E25E25
E23E23
E24E24

E19E19

E18E18

E5E5

E10E10

E6E6

E7E7

TEST
CONN

(CSR)

(TS2)

(TS1)

(NEG)

(78)
(79)

(80)
(81)

(7)
(8)

(9)
(10)
(11)
(12)
(13)
(14)
(19)
(20)

4

MAIN TRANSFORMER

(E17)

(E34)

ATC CONNECTION
CONFIGURATION

1

1

2

2

575
7
3

3
4

4
8

8

PRI

PIP

TORCH
SW

ATC MALE
CONNECTOR

ATC RECEIVER

SOL1

GAS
SOLENOID

W1

T5

SEC

BA

FACTORY INSTALLED OPTIONAL
TORCH MOUNTED GAS SOLENOID

PRESSURE
SWITCH

PS1

CLOSED WHEN
PRESSURE OK

MAIN
CONTACTOR

BA

5

T6

11 15

PRI

SEC

6

10

WHEN OPTIONAL TORCH
MOUNTED GAS SOLENOID
IS USED,SOL1 IS POWERED
BY T6 ONLY ,SOL2
POWERED BY P4-1,-2

Art # A-07154

1

APPENDIX A-20 Manual 0-2972

2

3

4

5

6

7

8

9

10

COMP DESCRIPTION LOCATION

FUSE, 6/10A 600V KTK

F1

MAIN CONTACTOR

W1

SWITCH, ON/OFF

SW1

SWITCH, RUN/SET/RAR

SW2

FAN, 4.5" 220VAC

M1

GAS SOLENOID

SOL1

PRESSURE SWITCH

PS1

TEMP. SENSOR, IGBT HEATSINK

TS1

TEMP. SENSOR, INDUCTOR

TS2

AUX TRANSFORMER

T1

MAIN TRANSFORMER

T5

OUTPUT INDUCTOR

L1

B3

F5

C2

C2

B2

F5

F5

D2

E2

B3

C5

E6

A

E28E28

E29E29

E38
E39
E40
E41

E32E32
E33E33

23
24
25

OUTPUT DIODE

ASSEMBLY
19X1720

12

1314

24567

IGBT BOARD

ASSY 19X1721

GATE

J18 P18

DRIVE

28

27

GATE
DRIVE

J19

1

E36
E37

E42
E43

OUTPUT INDUCTOR

L1

ATC RECEIVER
ATC MALE CONNECTOR

2

121

E30E30

E31E31

2

121

T
O
R
C
H

P19

PLUGS INTO J22

*

ON MAIN BOARD

(LED PCB 19X1604)

AC

TEMP

GAS

DC

NOTES: UNLESS OTHERWISE SPECIFIED

1. DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS
IS FOR REFERENCE ONLY

OPTIONAL AUTOMATION INTERFACE CONNECTIONS

ALTERNATE 20-PIN HEADER

P1

J1

1

1
2
3
4
5
6
7
8

P3

2112
3

CSR

2

DC COMMON

3

+12VDC
4
5

TORCH SW ­6

TORCH SW +
7
8

Vo

19X2041

OPTIONAL

AUTOMATION
INTERFACE

J3

3

P4

J4

20

20

19

19

18

18

17

17

16

16

15

15

14

14

13

13

12

12

11

11

10

10

9

9
8

8

7

7

6

6

5

5

4

4

3

3

2

2

1

1

J2

10
11
12
13
14
15
16
17
18
19
20

(51)
(52)

J14 P14

1

1

2

2

3

3

4

4

5

5
6

6
7

7

8

8

(CSR)

(TS2)
(TS1)

(NEG)

(47)

1

(48)

2

(49)

3
4
5
6
7
8

ADAPTER HARNESS USED

WHEN REMOTE CURRENT
CONTROL IS USED WITH
AUTOMATION
(REPLACES CONNECTIONS
FROM J22 TO J14)

20-POSITION TERMINAL STRIP

1

+

2

TORCH SWITCH

3

-

4
5
6

OK TO MOVE
7
8
9

+

DIVIDED OUTPUT

-

REMOTE CURRENT CONTROL

DC COMMON

+

C&G

-

(56)

(+)

4

(57)

(59)

(61)

(63)

(58)

(60)

(62)

(64)

3
14
12

6

5

8

9

7

CPC

HOUSING

(-)

(+)
(-)

(+)
(-)

TORCH SWITCH

}

OK TO MOVE

}

SC-11

}

LOGIC COMMON
ARC VOLTS (C&G)

}

B

C

D

E

(E62)

WORK

E62

PILOT BOARD

ASSY 19X2086

E58

12 5 8

J28

+12V

GND
CSR

ISENSE

3

(46)

7

(E58)

6

Manual 0-2972 A-21 APPENDIX

J1

(52)

1
2

(51)

RAR OFF

(MODE SW) (C2)

DateByRevisionsRev

DateByRevisionsRev

AA

AA

AA

ECO 101136

AB
AC

ECO B028

AD

ECO B016 RWH 01/27/06

AE

Friday, January 27, 2006

Friday, January 27, 2006

Friday, January 27, 2006

Last Modified:

Last Modified:

Last Modified:

8

(REL)

DateByRevisionsRev

DLL 05/27/03

02/11/04HASECO 101314

HAS 06/09/04ECO 101429
RS 01/09/06

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Not For Release, Reproduction, or Distribution without Written Consent.

Not For Release, Reproduction, or Distribution without Written Consent.

Not For Release, Reproduction, or Distribution without Written Consent.

NOTE:

NOTE:

NOTE:

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF)

Capacitors are in Microfarads (UF)

Capacitors are in Microfarads (UF)

TITLE:

TITLE:

TITLE:

9

SCHEMATIC,

SCHEMATIC,

SCHEMATIC,

CM51 208/230V SYSTEM

CM51 208/230V SYSTEM

CM51 208/230V SYSTEM

THERMAL DYNAMICS

THERMAL DYNAMICS

THERMAL DYNAMICS
INDUSTRIAL PARK No. 2

INDUSTRIAL PARK No. 2

INDUSTRIAL PARK No. 2
WEST LEBANON, NH 03784

WEST LEBANON, NH 03784

WEST LEBANON, NH 03784
603-298-5711

603-298-5711

603-298-5711

10

PCB No:

PCB No:

PCB No:

Assy No:

Assy No:

Assy No:

SupersedesScale

SupersedesScale

SupersedesScale

Date:

Date:

Date:

05/27/03

Drawn: References

Drawn: References

Drawn: References

D.Lilja

Chk: App:

Chk: App:

Chk: App:

Sheet

Sheet

Sheet

11

11

11

of

of

of

DWG No:

Size

DWG No:

Size

DWG No:

Size

42X1150

D

42X1150

D

42X1150

D

Art # A-07154

F

APPENDIX 16: SYSTEM SCHEMATIC

(400-Volt and 460-Volt Units)

A

B

C

D

E

F

400/460V
1 PHASE
INPUT

400V
3 PHASE
INPUT

M1
FAN1

1

...OR...

400/460V
3 PHASE
INPUT

400V 'CE' VERSION
INCLUDES IN-LINE
EMC FILTER

230V

ON/OFF SW

MODE SW

RAR OFF

(PILOT PCB) (F6)

CURRENT ADJUST:
20 - 40 AMPS

CURRENT
CONTROL/
LED PCB
19X1604

IGBT
HEATSINK
TEMP

INDUCTOR
TEMP

INV ON
(RED)

LOGIC
ASSY 19X2000
ASSY 19X2283

28VAC B
28VAC A

RUN

(46)

L1

L2

L3

SW1

SET

SW2

J14

1
2
3

AC

4
5
6

TEMP

7
8

GAS

DC

NTC

tt

TS1

TS2

GND SIGNAL
GND SIGNAL

GND SIGNAL

PRESS GOOD

OVERTEMP
GND SIGNAL
GND SIGNAL
GND SIGNAL

GND SIGNAL

D8

TORCH SWITCH

POT WIPER

GATE DRIVE B RTN

GATE DRIVE B

GATE DRIVE A RTN

GATE DRIVE A

CURRENT SENSE

CURRENT SENSE
CURRENT SENSE RTN
CURRENT SENSE RTN

W1

W1

W1

CHASSIS
GND

(3)

(4)

(6)

(5)

(21)
(22)
(23)
(24)
(25)
(26)

P14

(35)

1

(36)

2

(37)

3

(38)

4

(39)

5

(40)

6

(41)

7

(42)

8

+12VDC
+12VDC

RUN/SET

28VAC A
GAS ON

CSR

DC OK

OVTEMP

AC OK

RTN

+12VDC

POT HIGH

POT LOW

- OUT

ISENSE

(1)

(2)

(44)

E14

P8 J8

1
2
3
4

1
2
343
4

P3

1
2
3
4
5
6
7
8

P22

1
2
3
4
5
6
7
8

P2 J2

1
2
3
4

P23

121

P1

1
2
3
4

W1

5
6
7
8

9
10
11
12
13
14
15
16
17
18
19

20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

TIP

1
2
3
4

J26P26

1
2

J3

1
2
3
4
5
6
7
8

J22

1
2
3
4
5
6
7
8

1
2
3
4

J23

2

J1

1
2
3
4
5
6
7
8

9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

2

E3

K4

F1 (1/4A 500V)

R94 (460V)

R93 (400V)

K3

SEE TABLE 1

+12V

K4

INRUSH

K3

FAN

POT HIGH
POT WIPER
POT LOW
+12V
AC
GAS
OVERTEMP
DC

K2

CONTACTOR ON

K5

SOLENOID ON

MAIN BOARD
ASSY 19X2033 (400V)
ASSY 19X2060 (460V)

CHASSIS GND

THRU SCREW TERMINAL

E16 E28

E2 E1

(FILTERING)

K4

T1

28VAC B 28VAC A

28VAC A
28VAC B

+18V

+18V

+18V

TO BIAS
SUPPLY

CSR

DC COMMON

PRESS GOOD

3

E5

E13

E18

GATE DRIVE A RTN

GATE DRIVE B RTN

K5

F2, 0.9A,
(RESETABLE)

K2

INPUT DIODE
ASSY 19X2073

J21 P21

GATE DRIVE A

J20 P20

GATE DRIVE B

CSR

TORCH SWITCH -

TORCH SWITCH +

Vo

CURRENT

SENSE

PIP RTN

PIP

TORCH SW

TORCH SW RTN

28VAC A

GND

28VAC B

+12V

CSR

ISENSE

121

121

2

E22

J9 P9

121

3
4

J5

1
2
3

J4 P4

1
2
3
4
5
6
7
8
9

10

10

2

2

3
4

E6
E8

E14
E16

1
2
3
4
5
6
7
8
9

E11

E12

E13

E15

E35

E4

E9

E8

E21

E20

E26
E25
E23
E24

E19

E18

E5

E10

E6

E7

E17

E34

TEST
CONN

MAIN TRANSFORMER

(CSR)

(TS2)

(TS1)

(NEG)

ATC CONNECTION
CONFIGURATION

(78)
(79)

(80)
(81)

(7)
(8)

(9)
(10)
(11)
(12)
(13)
(14)
(19)
(20)

(E17)

(E34)

1
2

3
4
8

4

1

2
5
757

3

4

8

T5

PRI

PIP

TORCH
SW

ATC MALE
CONNECTOR

ATC RECEIVER

SOL1

A

GAS
SOLENOID

PS1

SEC

BA

B

FACTORY INSTALLED OPTIONAL
TORCH MOUNTED GAS SOLENOID

PRESSURE
SWITCH

CLOSED WHEN
PRESSURE OK

W1

MAIN
CONTACTOR

5

T6

11 15

PRI

SEC

6

10

WHEN OPTIONAL TORCH
MOUNTED GAS SOLENOID
IS USED, SOL1 IS POWERED
BY T6 ONLY ,SOL2 POWERED
BY P4-1,-2

Art # A-07155

1

2

APPENDIX A-22 Manual 0-2972

3

4

5

6

7

8

9

COMP DESCRIPTION

F1

W1

SW1

SW2

M1 FAN, 4.5" 220VAC

SOL1 GAS SOLENOID

PS1 PRESSURE SWITCH

TS1

TS2

T1 AUX TRANSFORMER

L1

FUSE, 1/4A 500V FNQ

MAIN CONTACTOR

SWITCH, ON/OFF

SWITCH, RUN/SET/RAR

TEMP. SENSOR, IGBT HEATSINK

TEMP. SENSOR, INDUCTOR

MAIN TRANSFORMER

OUTPUT INDUCTOR

10

LOCATION

B3

F5

C2

C2

B2

F5

F5

D2

E2

B3

5C5T

E6

A

E28

E29

E32
E33

E38
E39

E40
E41

24
25

12231314

24567

IGBT BOARD

ASSY 19X1721

OUTPUT DIODE
ASSEMBLY
19X1720

GATE
DRIVE

J18

2

1

28

27

GATE
DRIVE

J19 P19

1

2

E36
E37

E42
E43

OUTPUT INDUCTOR

L1

P18

2

1

E30

E31

2

11

ATC RECEIVER
ATC MALE CONNECTOR

T
O
R
C
H

PLUGS INTO J22

*

ON MAIN BOARD

(LED PCB 19X1604)

AC

TEMP

GAS

DC

NOTES: UNLESS OTHERWISE SPECIFIED

1. DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS
IS FOR REFERENCE ONLY

COMP

19X2033 (400V) 19X2060 (460V)

R93

115X465-2 (0 ohm)

XXXXXXXX

R94

F1

1/4A 500V

OPTIONAL AUTOMATION INTERFACE CONNECTIONS

ALTERNATE 20-PIN HEADER

J1

P1

J14 P14

1

1
2

2

3

3
4

4

5

5
6

6

7

7

8

8

(CSR)

(NEG)

(47)

1

(48)

2

(49)

3
4
5
6
7
8

ADAPTER HARNESS USED

WHEN REMOTE CURRENT
CONTROL IS USED WITH
AUTOMATION
(REPLACES CONNECTIONS
FROM J22 TO J14)

(TS2)
(TS1)

1

1
2
3
4
5
6
7
8

P3

2112
3

CSR
DC COMMON

2

+12VDC

3
4

TORCH SW -

5

TORCH SW +

6
7
8

Vo

19X2041
OPTIONAL

AUTOMATION
INTERFACE

J3

3

P4

J4

20

20

19

19

18

18

17

17

16

16

15

15

14

14

13

13

12

12

11

11

10

10

9

9
8

8

7

7

6

6

5

5

4

4

3

3

2

2

1

1

(51)
(52)

TABLE 1

ASSEMBLY

20-POSITION TERMINAL STRIP

J2

1

+

2

TORCH SWITCH

3

-

4
5
6

OK TO MOVE
7
8
9

+

10

DIVIDED OUTPUT

11

-

12
13
14

REMOTE CURRENT CONTROL

15
16
17

DC COMMON

18

+

19

C&G

20

-

(56)

4

(57)

3

(58)

14

(59)

12

(60)

6

(61)

5

(62)

8

(63)

9

(64)

7

CPC

HOUSING

XXXXXXXX

115X465-2 (0 ohm)

1/4A 500V

(+)

TORCH SWITCH

}

(-)

}

OK TO MOVE

(+)

SC-11

}

(-)

LOGIC COMMON

(+)

ARC VOLTS (C&G)

}

(-)

B

C

D

E

(E62)

TOROID (INSTALLED
ON 400CE ONLY)

WORK

E62

PILOT BOARD

ASSY 19X2086

E58

3

J28

12 85

(46)

7

(E58)

+12V

GND
CSR

ISENSE

6

Manual 0-2972 A-23 APPENDIX

J1

(52)

1
2

(51)

RAR OFF

(MODE SW) (C2)

PCB No:

PCB No:

10

PCB No:

Assy No:

Assy No:

Assy No:

Date:

Date:

Date:

Drawn: References

Drawn: References

Drawn: References

Chk: App:

Chk: App:

Chk: App:

Size

Size

Size

SupersedesScale

SupersedesScale

SupersedesScale

05/27/03

D.Lilja

Sheet

Sheet

Sheet

11

11

11

of

of

of

DWG No:

DWG No:

DWG No:

42X1151

D

42X1151

D

42X1151

D

Art # A-07155

F

DateByRevisionsRev

DateByRevisionsRev

DateByRevisionsRev

(REL)

ECO 101136

AA

AA

AA
AB
AC

ECO B028

AD

ECO B016 RWH 01/27/06

AE

Friday, January 27, 2006

Friday, January 27, 2006

Friday, January 27, 2006

Last Modified:

Last Modified:

Last Modified:

8

DLL 05/27/03

HAS 02/11/04ECO 101314

HAS 06/09/04ECO 101429

RS

01/09/06

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Not For Release, Reproduction, or Distribution without Written Consent.

Not For Release, Reproduction, or Distribution without Written Consent.

Not For Release, Reproduction, or Distribution without Written Consent.

NOTE:

NOTE:

NOTE:

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF)

Capacitors are in Microfarads (UF)

Capacitors are in Microfarads (UF)

TITLE:

TITLE:

TITLE:

9

SCHEMATIC,

SCHEMATIC,

SCHEMATIC,

CM51 400/460V SYSTEM 1O/3O

CM51 400/460V SYSTEM 1O/3O

CM51 400/460V SYSTEM 1O/3O

THERMAL DYNAMICS

THERMAL DYNAMICS

THERMAL DYNAMICS
INDUSTRIAL PARK No. 2

INDUSTRIAL PARK No. 2

INDUSTRIAL PARK No. 2
WEST LEBANON, NH 03784

WEST LEBANON, NH 03784

WEST LEBANON, NH 03784
603-298-5711

603-298-5711

603-298-5711

APPENDIX 17: Publication History

Cover Date Rev Comments

5/5/04 - - Manual released.

6/23/04 - - Updated system schematics per ECO 101429.

4/28/06 AA Updated system schematics per ECO B016. Added c/n for logic board for mechanized

units. Updated torque spec for replacement input diode per ECO 101948. Added publica
tion history. Started using new cover styles.

9/29/06 AA.01 Added patent information, newer revision control and inside rear cover information.

4/13/07 AB.01 Updated C & Cr, Sect. 6, revised 6.06, Item # 2, Assembly, Pilot PCB, Catalog #: 9-8337,

updated Rear and Inside Cover.

APPENDIX A-24 Manual 0-2972

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road
Denton, Tx 76207 USA
Telephone: [phone]
800-426-1888
Fax: [phone]
Email: [e-mail]

Thermadyne Canada

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

Thermadyne Europe

Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: [phone]
Fax: [phone]

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085

Cigweld, Australia

71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: [phone]
Fax: [phone]

Thermadyne Italy

OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: [phone]
Fax: [phone]

Thermadyne, China

RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: [phone]
Fax: [phone]

Thermadyne International

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

Corporate Headquarters

16052 Swingley Ridge Road
Suite 300
St. Louis, MO 63017

Telephone: [phone]
Email: [e-mail]

www.thermadyne.com