Thermal Dynamics 81 CUTMASTER Service Manual

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CUTMASTER

PLASMA CUTTING SYSTEM

Service Manual

A-04517

Rev. AC.01 Date: April 13, 2007 Manual # 0-2957 Operating Features:

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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™ 81 Operating Manual Number 0-2957

Covered under U.S. Patents.

Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermal-dynamics.com

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: April 13, 2007

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

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

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 Scope ........................................................................................................... 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..................................................................... 5-3

5.06 Left Side Internal Parts Replacement ........................................................... 5-4

5.07 Rear Panel Parts Replacement ..................................................................... 5-7

5.08 Right Side Internal Parts Replacement ......................................................... 5-8

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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 Component Replacement Parts ........................................ 6-4

6.06 Rear Panel Replacement Parts .................................................................... 6-6

6.07 Right Side Internal Component Replacement Parts ...................................... 6-7

6.08 Options and Accessories ............................................................................. 6-8

PATENT INFORMATION ............................................................................................................ 6-9

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

APPENDIX 2: SEQUENCE OF OPERATION

(BLOCK DIAGRAM) .......................................................................................................... A-2

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

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

APPENDIX 5A: MAIN PC BOARD WIRING LAYOUT - 208/230-Volt Units ................................ A-6

APPENDIX 5B: MAIN PC BOARD WIRING LAYOUT -

400-Volt, 415-Volt 460-Volt, and 600-Volt Units .................................................................. A-7

APPENDIX 6: LED/POT PC BOARD LAYOUT .......................................................................... A-8

APPENDIX 7: INPUT DIODE PC BOARD LAYOUT .................................................................. A-9

APPENDIX 8: IGBT CIRCUIT PC BOARD LAYOUT ............................................................... A-10

APPENDIX 9: OUTPUT DIODE PC BOARD LAYOUT ............................................................ A-11

APPENDIX 10: OUTPUT BOARD WIRING DIAGRAM ............................................................ A-12

APPENDIX 11: PILOT PC BOARD LAYOUT ........................................................................... A-13

APPENDIX 12: 28VAC CIRCUIT DIAGRAM ........................................................................... A-14

APPENDIX 13: DATA TAG INFORMATION ............................................................................. A-15

APPENDIX 14: TORCH PIN-OUT DIAGRAMS ......................................................................... A-16

APPENDIX 15: TORCH CONNECTION DIAGRAMS ................................................................ A-17

APPENDIX 16A: SYSTEM SCHEMATIC, 208/230-Volt Units .................................................. A-18

APPENDIX 16B: SYSTEM SCHEMATIC,

400-Volt, 415-Volt and 460-Volt Units.............................................................................. A-20

APPENDIX 16C: APPENDIX 16C: SYSTEM SCHEMATIC, 600-Volt Units ............................. A-22

APPENDIX 17: Publication History .........................................................................................

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

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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.”

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• 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 0-2957

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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 0-2957 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.

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• 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 0-2957

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

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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 0-2957 1-5 GENERAL INFORMATION

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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 0-2957

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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 0-2957 1-7 GENERAL INFORMATION

Page 14

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 Component s

(Parts and Labor)

Torc h 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 May 23, 2005

GENERAL INFORMATION 1-8 Manual 0-2957

Page 15

SECTION 2:

INTRODUCTION

This Service Manual covers all types. Particular attention is required in the Trouble-Shooting Section (Section 4) to ensure that the technician selects the proper test points and measurements for the Power Supply being serviced.

2.01 Scope Of Manual

This manual provides service instructions for Thermal Dynamics CutMaster™ 81 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 (0-2956).

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.

The CutMaster™ 81 Power Supply is available for the following input voltages:

• 208/230-Volt Single-Phase

• 400-Volt Three-Phase

• 415-Volt Three Phase

• 460-Volt Three-Phase

• 600-Volt Three-Phase

The 460-Volt Three-Phase unit may be converted for SinglePhase input power with a change of input power cord.

2.02 General Service Philosophy

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

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.

Manual 0-2957 2-1 INTRODUCTION

Printed Circuit Board Assemblies to be returned must be properly packaged in protective material and returned intact per normal procedures.

2.03 Service Responsibilities

The service technician should be familiar with the 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).

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INTRODUCTION 2-2 Manual 0-2957

Page 17

SECTION 3: DESCRIPTION

3.01 Scope

The purpose of this section is:

• To familiarize the service technician with the capabilities and limitations of the equipment;

• To provide an overall understanding which will allow the technician, in turn, to properly train customer 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 81 Power Supply Specifications

208 / 230 VA C (187 - 253 VA C), S ingl e P has e, 50/60 Hz 400 VAC (360 - 440 VA C), Three Phase, 50/ 60 Hz

Inpu t P o w e r

Input Power Cable Out put Current Power Supply Gas Fi ltering Abi l i t y

Ambi ent Temperature

208/230V

and 460V Units

400V and 415V Uni ts

600V Uni ts

* NOTE: The duty c yc l e will be reduc ed if t he prim ary i nput power (AC)

415 VAC (370 - 460 VA C), CE Three Phase, 50 Hz 460 VAC (414 - 506 VA C), S i ngle P has e, 60 Hz 460 VAC (414 - 506 VA C), Three Phase, 60 Hz 600 VAC (517 - 632 VA C), Three Phase, 60 hz Cable for 208/230 V A C uni t i ncludes pl ug. 20 - 60 Amps , Continuous l y Adjustabl e Part iculat es to 20 Microns

CutMaster 81 Power Sup ply Duty Cy cl e *

40° C (104° F)

IEC

Rating Duty Cycle Current 60A 60A 6 0A 60A 45A 4 5A DC Volt age 104V 109V 104V 109V 98V 98V Duty Cycle Current 60A n/a 6 0A n/a 45A n/a DC Volt age 104V n/ a 104V n/a 98V n/ a Duty Cycle Current 60A 60A 6 0A 60A 43A 4 3A DC Volt age 104V 109V 104V 109V 97V 97V

TDC

Rating

IEC

Rating

TDC

Rating

60% 100%

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 0-2957 3-1 DESCRIPTION

NOTE:

Page 18

Art # A-03578

Handle and Leads Wrap

Control Panel

Torch Leads Receptacle

Work Cable and Clamp

Gas Pressure Regulator /

Ports for Optional Automation Interface Cable

Gas Pressure Gauge

Input Power Cord

Filter Assembly

Gas Inlet Port

Art # A-03738

DESCRIPTION 3-2 Manual 0-2957

Page 19

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 (up to 60 amps).

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

83 lb / 37.6 kg

17.3 in / 439 mm

27.5 in / 696 mm

12.4 in /

A-03572

315 mm

3.03 Air Regulator/Filter Assembly Specifications

The following specifications apply to the Air Regulator/Filter Assembly only:

1. Operating Pressure

65 psi (4.5 bar)

2. Maximum input air supply pressure

125 psi (8.6 bar)

Manual 0-2957 3-3 DESCRIPTION

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DESCRIPTION 3-4 Manual 0-2957

Page 21

SECTION 4:

4.03 System Theory

TROUBLESHOOTING

4.01 Introduction

This section provides service diagnostics for the CutMaster 81 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 0-2957 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.

CutMaster 81 Logic Boa rd Indi ca tors

Indicator M ean ing

D13 Invert er ON D33 Torch S wit ch O N D25 Dra g Circ u i t ON

Page 22

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 0-2957

Page 23

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 0-2957 4-3 TROUBLESHOOTING

Page 24

4.06 Circuit Fault Isolation

B. Initial Setup Conditions

A. Controls and Indicators

Art # A-03845

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. At output settings over 40 amps, circuitry in the power supply automatically reduces output current to 40 amps if the torch tip contacts the workpiece.

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

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

5. TEMP indicator turns on when internal sensors

detect temperatures above normal limits.

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 0-2957

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

• DC indicator is OFF

• Gas flows

• Fans operate

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.

Page 25

D. Pilot Arc Test

1. Activate the torch (press torch switch on the handle, send START signal from CNC Control, or press the torch switch on the Remote Pendant) to establish a pilot arc and note the following:

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.

• 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:

• 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.

Upper screws

Lower screws

Ground wire

Art # A-03792

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.

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.

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.

B. Main power line fuses blow immediately after the

ON/OFF Switch is turned on.

1. Faulty Input Diode

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

as necessary.

Manual 0-2957 4-5 TROUBLESHOOTING

Page 26

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.

4. Shield cup not fully tightened on torch head.

a. Check shield cup for proper installation. Do

not overtighten.

5. Main power line fuses blown

a. Replace main power line fuses.

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.

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

Measure for 28 VAC on Main PC Board from J23-1 to J23-3.

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

Board.

J16

J17

J15

J11

E15

J25

E10

E20

E22

TP4

FUSE

INPUT DIODE

TP1

J23

J24

J34

J32

J29

J33

J18

J27

J43

E32

J26

E27

E30

Art # A-03651

IGBT A

Main Printed Circuit Board Layout (logic board not shown)

TROUBLESHOOTING 4-6 Manual 0-2957

E33

J30

J31

E23

IGBT B

Page 27

11. Faulty ON/OFF switch

4. Faulty Temperature Sensor / Switch

Measure for 28 VAC on the Main PC Board between J18-5 to J18-6.

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 TP4 to

TP1.

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

Board.

D. Fans do not run; AC , GAS and TEMP

indicators ON, DC indicator off

Art # A-03984

a. Shut input power off. Check IGBT Heatsink

Temp Sensor (TS1). Disconnect wire connector P29 from terminal J29 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 P32 from terminal J32 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;

TEMP GAS and DC indicators OFF

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(s)

Measure for 230 VAC (±) on the Main PC Board from J15-1 to J15-5, and from J15-2 to J15-6.

• If voltage at J15-1 to J15-5 is correct, replace lower Fan (M1).

• If voltage at J15-2 to J15-6 is correct, replace upper Fan (M2).

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-E;

repair as necessary.

6. Faulty Logic Board

Manual 0-2957 4-7 TROUBLESHOOTING

a. Replace logic board.

Page 28

F. RUN / RAPID AUTO RESTART /SET switch in

RUN or RAPID AUTO RESTART position; AC

indicator

ON; TEMP , GAS , and DC

indicators OFF

Art # A-03986

1. Gas pressure too low

a. Set operating pressure per pressure setting la-

bel on power supply.

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.

TP4

TP2

TP1

TP3

D13

TP6

D33

P1-7

P1-9

TP9

TP10

TP11

TP5

TROUBLESHOOTING 4-8 Manual 0-2957

D25

TP8

Logic Board Layout

TP7

Art # A-03654

Page 29

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

GAS indicator

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 output power PC Board.

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

Refer to Appendix pages, Output Board Wiring Diagram. Check output power PC Board for continuity between terminals E35 and E64. If continuity is found, replace Output Power PC Board.

Manual 0-2957 4-9 TROUBLESHOOTING

Page 30

J16

J17

J15

E22

TP4

FUSE

TP1

J23

J24

J34

J32

J29

J33

J18

J27

J11

E15

J25

E10

E20

Art # A-03651

INPUT DIODE

IGBT A

E33

J30

J31

E23

Main Printed Circuit Board Layout (Logic PCB Not Shown)

J43

E32

J26

E27

E30

IGBT B

TROUBLESHOOTING 4-10 Manual 0-2957

Page 31

4.08 Pilot Arc Problems

WARNING

3. Faulty IGBT(s)

a. Measure between the following points on the

IGBTs:

• IGBT A: 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

Art # A-03988

E10 to E20

• IGBT B: E23 to E27

E27 to E30

Voltage should be approximately 20 vdc before the start signal is active. If voltage measures greater than 100 vdc when the start signal is active, replace the respective IGBT(s).

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

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 0-2957 4-11 TROUBLESHOOTING

Page 32

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

Art # A-03621

CAUTION

Turn off input power for the following tests.

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

connect wire connector P29 from terminal J29 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 P32 from terminal J32 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 Main PC Board

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

TP4 and TP1. If (±) 0 vdc is present, replace Main PC Board.

6. Faulty Fan(s)

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

J15-1 to J15-5, and from J15-2 to J15-6.

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.

• If voltage at 15-1 to J15-5 is correct, replace upper fan (M1).

• If voltage at 15-2 to J15-6 is correct, replace lower fan (M2).

TROUBLESHOOTING 4-12 Manual 0-2957

Page 33

D. Gas flows; AC indicator and GAS indicators

2. Oil/moisture in air lines

ON; TEMP indicator off; DC indicator

off or blinks on/off once.

Art # A-03991

1. Faulty IGBT or Output Diode Module Assembly(s)

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

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

• Wire #62 to Pilot Board terminal E62

Art # A-03992

1. Gas pressure set incorrectly (too high)

a. Reset gas pressure per pressure setting label on

power supply.

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

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.

Manual 0-2957 4-13 TROUBLESHOOTING

Page 34

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.

• If not, replace Main PC Board.

5. Faulty Main Input Contactor.

a. Check per Subsection 4.10-D.

B. When operating the amperage drops off after the

main cutting arc starts.

1. Torch tip contacts workpiece

Lift the torch tip off the work. At output settings over 40 amps, circuitry in the power supply automatically reduces output current to 40 amps if the torch tip contacts the workpiece.

2. Faulty Pilot Board

a. With power off and wires E58 and E62 discon-

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

J16

J17

J15

J11

E15

J25

E10

E20

E22

TP4

FUSE

INPUT DIODE

TP1

J23

J24

J34

J32

J29

J33

J18

J27

J43

E32

J26

E27

E30

Art # A-03651

IGBT A

Main Printed Circuit Board Layout (logic board not shown)

TROUBLESHOOTING 4-14 Manual 0-2957

E33

J30

J31

E23

IGBT B

Page 35

4.10 Test Procedures

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.

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

0.75

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.

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

B. Diode Testing Basics

WARNING

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

Forward Bias

Diode Conducting

Diode Test Symbol

Anode

Cathode

COM

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”.

Art # A-00306

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.

Manual 0-2957 4-15 TROUBLESHOOTING

Reverse Bias

Diode Not Conducting

Cathode

Anode

Testing Diode Reverse Bias

COM

Page 36

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

8. Reconnect all cables.

C. Diode Module Board Tests

WARNING

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

1. Input Diode Module Board Circuit Test

For 208/230-Volt Power Supplies:

208/230V Input Diode PCB

Met e r (+) M e ter (-) Indicat ion

E7 E1 Open E1 E 7 Diode Drop

E15 E 1 Diode Drop

E1 E15 Open

E15 E 7 Diode Drop *

E7 E15 Open

* Indicat i on can be twice

other indicati ons.

a. Remove AC power. Refer to Appendix 5-A or 5-B,

Main PCB Wiring diagram.

b. Check Input Diode for shorted input diode. With

an ohmmeter set on the diode range make the following checks from Main PC Board to Input Diode:

For 400-Volt, 415-Volt, 460-Volt, and 600-Volt Power

Supplies:

400V, 415V , 460V , and 600V

Input Diode Indications

Meter + Met er - Indicati on

E15 E1 Diode Drop

E1 E15 Open

E15 E2 Diode Drop

E2 E15 Open

E15 E3 Diode Drop

E3 E15 Open E7 E1 Open E1 E7 Diode Drop E7 E2 Open E2 E7 Diode Drop E7 E3 Open E3 E7 Diode Drop E7 E15 Open

E15 E7 Diode Drop*

* Indicat ion can be twic e

other indic ations .

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

rection and an open in the other direction for each check. Replace the Input Diode Module Board if the readings do not match the chart.

d. If Input Diode Module Board is shorted, make the

following checks with an ohmmeter at the Main Contactor (W1):

Met e r (+) M eter (-) Indicat i on

L1 T1 Open L2 T2 Open L3 T3 Open

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

2. Output Diode Module Board Circuit Test

a. Use an ohmmeter set on the diode function and

make the following measurements on the Output Diode Module Boards to Power Output PC Board.

Output Diode A Output Diode B

Meter + M eter - Met er + M et er -

E37 E58 E 36 E 57 Diode Drop * E58 E37 E57 E36 Open E37 E47 E 36 E 49 Diode Drop E47 E37 E49 E36 Open E58 E47 E57 E49 Open E47 E58 E 49 E 57 Diode Drop

* Indicat i on can be twice other indi c ations .

Indication

TROUBLESHOOTING 4-16 Manual 0-2957

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

rection and an open in the other direction for each check. Replace the Output Diode Module Board(s) if the readings do not match the chart.

Page 37

3. IGBT Module Board Circuit Test

a. Use an ohmmeter set on the diode function and

make the following measurements on the IGBT Module Board(s) to the Main PC Board.

IGBT PCB A IGBT PCB B

Indication

Met er + M et er - M et er + Met er -

E10 E4 E 27 E 23 Diode Drop

E4 E10 E23 E27 Open E10 E20 E27 E30 Open E20 E10 E 30 E 27 Diode Drop

E4 E20 E23 E30 Open E20 E4 E 30 E 23 Diode Drop *

* Indicat i on can be twice other indi c ations .

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

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

D. Main Input Power Test

WARNING

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 on Front Panel is OFF, check for proper AC input voltage between input cables on the Main Contactor. Input voltage should be as shown in the following chart. If not, check for proper voltage at the main power source.

TP4

TP2

TP1

TP3

D13

TP6

D33

P1-7

P1-9

TP9

TP10

TP11

TP5

Manual 0-2957 4-17 TROUBLESHOOTING

D25

TP8

Logic Board Layout

TP7

Art # A-03654

Page 38

Contactor Volt age Readings

Nominal

Inp u t Volta g e

Contactor

Points

Voltage

Range

208/230VA C L1, L2 187-253VAC

400VAC L1, L3 360-440VA C 415VAC L1, L3 370-460VA C 460VAC L1, L3 414-506VA C

2. Check for 28 VAC at J23-1 to J23-3 on the Main PC Board.

a. If greater than 30 VAC, input line power is too

high.

b. If there is no AC power, check the fuse. If the

fuse is okay, the auxiliary transformer is faulty. Replace the Main PC Board.

E. Gas Solenoid Circuit Test

To E2

To E3

Connections to

Main PCB

To E1

T1 T2 T3

L1 L2 L3

Input Side

#12

#13

400 / 415 / 460 / 600-Volt Main Input Contactor

(Three-Phase Input Power Shown)

Main Contactor

Art # A-03194

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 28 VAC across Solenoid wires #8 and #9. Refer to System Schematic in Appendix Section.

• If 28 VAC is present, replace Solenoid/Pressure

Switch Assembly.

• If 28 VAC is not present, check for 65 psi (4.5

bar) at the pressure regulator.

3. Check for less than 2 vdc at P1-7 to TP1 on Logic Board.

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

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

#12

#13

Input Side

208/230-Volt Main Input Contactor

TROUBLESHOOTING 4-18 Manual 0-2957

#78

T1 T2 T3 T4

L1 L2 L3 L4

Main Contactor

Art # A-03212

Page 39

F. Output Power Tests

2. Gate Drive & Sensing

1. No DC Output

1. Activate the torch.

• If INV ON indicator D13 on Logic PC Board does not turn ON, then replace the Logic PCB.

• If the INV ON indicator D13 blinks ON then OFF immediately, perform the following test:

2. Turn input power OFF, and bleed down the system.

3. Attach a #12 wire jumper between the work lead and terminal E35 or E62 on the Output Power PC Board on the right side of the power supply.

4. Remove the tip and electrode from the torch.

WARNING

The next step will defeat the safety interlock feature. Proceed with caution.

1. Shut off input power. Replace the torch tip and electrode. Remove the jumper betweenthe work lead and terminal E35 or E62 on the Output Power PC Board.

2. Install a jumper between TP1 and TP7 on the Logic Board. Refer to Logic Board layout.

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

4. Activate the torch. After two seconds INV ON Indicator (D13) 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 remains on, then check for

at least 2 vdc between TP-1 to TP-11 and between TP-1 to TP-10 on the Logic PCB. Refer to Logic Board Layout.

• If no voltage, replace Logic PC Board.

• If voltage is correct, measure for at least 2 vdc between points as in the following chart:

IGBT A IGBT B

E11J3E11J2B E19 J10A E19 J10B

5. Turn on primary input power and the gas supply. Activate the torch switch. Gas should flow, then stop after 2 seconds. Front panel DC indicator should turn on.

6. Measure open circuit voltage between E61(+) to E43 (-) at the Output Power PC Board. Voltage should be greater than 200 V. If voltage is less than 10 V, refer to the diode test measurements in Section 4.10-C.

• If voltage is 0, replace Main PCB.

This completes the test procedures.

Manual 0-2957 4-19 TROUBLESHOOTING

Page 40

This Page Left Blank

TROUBLESHOOTING 4-20 Manual 0-2957

Page 41

SECTION 5:

REPLACEMENT

PROCEDURES

5.01 Scope

This section describes parts replacement procedures which may be performed on the CutMaster 81 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. A ground strap is included with each replacement board 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.

Manual 0-2957 5-1 REPLACEMENT PROCEDURES

WARNING

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

Page 42

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

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

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.

B. Tube Handle Replacement

1. Remove the cover per subsection 5.04-A.

2. Remove the Fan Assembly Panel per section

5.08-C.

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. Loosen the lower screws securing the cover to the base.

Upper screws

Lower screws

3. Remove the four bolts and star washers securing the frame to the base of the unit.

4. Move the input power cable, torch leads and work cable inside the handle. Lift the base of the unit away from the Tube Handle. Leave the rear panel fastened to the base assembly.

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

6. Install the replacement Tube Handle by reversing steps 1-4.

7. Replace the Fan Assembly Panel per section 5.08C.

8. Re-install the Power Supply cover.

Art # A-03792

2. Carefully lift the cover up and away from the unit for access to the ground wire connection on the inside of the cover.

REPLACEMENT PROCEDURES 5-2 Manual 0-2957

Ground wire

Art # A-02847

Page 43

5.05 Front Panel Parts Replacement

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

WARNING

C. RUN RAPID AUTO RESTART / SET Switch

Replacement

1. Remove the cover per subsection 5.04-A.

2. Disconnect the wires on the rear of the Switch. Note the location of each wire, as shown:

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

A. Current (A) Control Knob Replacement

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

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

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

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

B. ON/OFF Switch Replacement

1. Remove the cover per subsection 5.04-A.

2. Disconnect the wires on the rear of the ON/OFF Switch. Note the location of each wire, as shown below:

Top clip

Wire #46

Wire #26

Wire #25

Art # A-03906

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

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

D. POT/LED PC Board Replacement

Follow the antistatic procedures provided in subsection

5.02.

1. Remove the cover per subsection 5.04-A.

2. Remove Current Knob per Subsection 5.05-A.

Top clip

Wire #21

Wire #24

Wire #22

Wire #23

Art # A-02774

3. Squeeze together the clips on the top and bottom of the Switch. Remove the Switch through the Front Panel.

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

3. Disconnect wire harness 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 E61 (WORK) terminal on the Power Output PC Board, located on the right 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.

a. Ensure that the replacement Work Cable

passes through the grommet in the Fan Assembly Panel.

b. Secure the Cable to the Work terminal on the

Power Output PC Board and securing the strain relief.

Manual 0-2957 5-3 REPLACEMENT PROCEDURES

Page 44

5.06 Left Side Internal Parts Replacement

Refer to subsection 6.05 Left Side Internal Component Replacement Parts and overall detailed drawing.

WARNING

Input Side

To E3

To E2

Connections to

Main PCB

To E1

T1 T2 T3

L1 L2 L3

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 from the fuse holder.

3. Install replacement fuse.

4. Reinstall the power supply cover.

B. Main Input Contactor Replacement

1. Remove the cover per subsection 5.04-A.

2. Label all wires connected to the Input Contactor.

3. Disconnect wires to the Input Contactor from the input cable.

4. Disconnect all other wires connected to the Input Contactor.

5. Remove the two nuts and washers securing the Input Contactor to the base of the power supply.

6. Position the replacement Input Contactor with the row of connectors labeled L toward the rear of the Power Supply. Fasten in place with the hardware removed previously.

7. Complete the wiring connections as shown.

NOTE

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

#12

#13

Main Contactor

Art # A-03194

400-Volt, 415-Volt, 460-Volt, and 600-Volt Input

Contactor (3 - phase input power connections

shown)

#78

T1 T2 T3 T4

L1 L2 L3 L4

#12

#13

Input Side

Main Contactor

Art # A-03212

8. Reinstall the power supply cover.

REPLACEMENT PROCEDURES 5-4 Manual 0-2957

208 / 230-Volt Input Contactor

Page 45

C. Logic PC Board Replacement

Follow the antistatic procedures in Subsection 5.02. The Logic PC Board connects to the Main PC Board through an extender board perpendicular to both boards.

1. Remove the cover per subsection 5.04-A.

2. Refer to Section 6.05, Left Side Internal Replacement Parts.

3. Remove the bolts in each corner of the Logic PC Board.

4. Detach the Logic PC Board and the extender board from the Main Power PC Board. Detach the extender board from the Logic Board.

5. Install the replacement Logic PC Board by reversing the above steps. The pins on the right edge of the Logic PC Board must fully engage the sockets on the edge of the extender board. The extender board must fully engage sockets on the Main Power PC Board.

D. IGBT Circuit Board or Input Diode Board

Replacement

5. Remove screw(s) securing PC Board(s) to the heatsink and remove board(s) from the Power Supply.

6. Use isopropyl alcohol and a clean rag to clean the heatsink or chassis area behind the component being replaced. Clean the large flat surface on the back of the replacement component. Do not scratch or abrade the surface.

7. The thermal pad(s), provided with the replacement part, is a thin metal pad. Remove any loose protective paper coverings from the pad(s).

NOTE

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

8. Install replacement components as follows:

For Input Diodes:

Slot

Follow the antistatic procedures in subsection 5.02. The Power Supply includes two IGBT Circuit PC Boards.

NOTE

Follow the electrostatic discharge instructions provided with the replacement component to prevent damage to the component.

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

1. Remove cover per subsection 5.04-A.

2. Turn the Power Supply onto its side.

3. Locate the IGBT Circuit PC Boards or Input Diode mounted within the Main Power PC Board. Refer to Appendix pages for location and position.

4. For IGBTs, remove the small jumpers between the IGBT and the Main PC Board. Transfer these jumpers to the replacement IGBT. Label, then remove all other wire connections to the Board(s) being replaced. Note the routing of wires. Ensure that the wires are put back in the same place when installing the replacement module.

Thermal Pad

Diode

Assembly

Art # A-03950

Input Diode Replacement

a. Apply the thermal pad to the flat surface of

the diode. Align the pad with the rectangular flat surface on the back of the device.

b. Align the diode horizontally, with its longer

edges perpendicular to the power supply base.

c. Secure the device and rectangular pad to the

chassis with the replacement screws and washers.

9. Torque screw(s) to 35 in-lb. (3.95 Nm).

NOTE

Failure to torque properly will cause component damage.

Manual 0-2957 5-5 REPLACEMENT PROCEDURES

Page 46

10. Connect wires per the chart.

E. Main Power PC Board Replacement

CutMas ter 81 Input Diode Connections

208/230V Units

Input Diode To Main P CB Input Diode To Main PCB

E5 E1 E5 E1

E13, E18 E2

E6, E8 E7 E6, E8 E7

E14, E16 E15 E14, E16 E15

400V, 415V , 460V,

600V Units

E13 E2 E18 E3

For IGBTs:

a. Apply a round thermal pad to the heatsink

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

Round

Output Diode or IGBT

Washer

Screw

Tape

Thermal Pad

Tape

Follow the antistatic procedures in subsection 5.02.

1. Remove cover per subsection 5.04-A.

2. Remove the Logic PC Board per subsection 5.06-C.

3. Disconnect all wire and cable connections to the Main PC Board. Refer to the Main PC Board Wiring Diagrams in the Appendix Pages if necessary. Straighten the connections to the smaller PC Boards to be perpendicular to the Main PC Board.

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

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

Screw locations

Art # A-03702

b. Secure replacement board(s) with the screw

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

9. Torque screw(s) to 17 in-lb. (1.9 Nm).

NOTE

Failure to torque properly will cause component damage.

10. Connect wires per the chart.

CutMaster 81 IGBT Connecti ons

IGBT A IGBT B

IGBT A

Connector

To Ma in PCB

Connector

IGBT B

Connector

To Main PCB

Connector

J3 J25 J3 J31 J7 J30 J7 J26

E9, E11 E10 E9, E11 E27 E19, E 21 E20 E 19, E21 E30 E12, E17 E4 E12, E17 E23

11. Stand the unit upright; reinstall the cover.

Art # A-03165

7. Carefully remove the original PC Board from the

unit.

8. Transfer the Logic PC Board standoffs to the replacement Main PC Board.

9. Install the replacement PC Board by reversing the steps above. It may be easier to install the PC Board if the Power Supply is turned on its right side first. Refer to the charts in subsection 5.06-D for input diode and IGBT wiring connection points.

F. EMI Filter Replacement (CE Units only)

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.

REPLACEMENT PROCEDURES 5-6 Manual 0-2957

Page 47

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

6. Re-install the Power Supply cover.

B. Filter/Regulator Bracket Replacement

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

7. Test the Power Supply for proper operation.

5.07 Rear Panel Parts Replacement

Refer to subsection 6.06 for parts list and overall detailed drawing.

WARNING

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

A. Filter/Regulator Assembly Replacement

WARNING

Disconnect the gas supply at the source and bleed down the system before attempting this procedure.

1. Disconnect the gas input hose from the Filter/ Regulator Assembly on the Rear Panel of the unit.

2. Remove the four bolts securing the Regulator Mounting Bracket to the Rear Panel.

3. Disconnect the black gas tube from the Filter/ Regulator Assembly Adapter Fitting. Hold a wrench or similar tool against the locking ring on the Fitting and pull on the tube to release it.

4. Remove 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.

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. Input Power Cable Replacement

1. Remove the cover per subsection 5.04-A.

2. Locate and label the input power cable connections and disconnect the cable.

3. Unthread the retaining nut on the Input Cable Strain Relief on the inside of the Rear Panel and remove the Input Power Cable from the unit.

4. Install the replacement Input Power Cable by reversing the above steps. The Input Power Cable ground wire requires a ring terminal.

D. Rear Panel Replacement

WARNING

Disconnect primary input power and the gas supply at the source and bleed down the system before performing this procedure.

1. Remove the cover per subsection 5.04-A.

2. Remove the primary input power cable per section 5.07-C.

3. Remove the Regulator/Filter Assembly per section 5.07-A.

4. Remove two bolts at the bottom corners of the Rear Panel.

5. Remove one nut on a stud on the inside of the Rear Panel, at the rear edge of the center chassis.

6. Replace the Rear Panel by reversing the above steps.

Manual 0-2957 5-7 REPLACEMENT PROCEDURES

7. If not already done, attach the data tag(s), provided with the replacement Rear Panel. Position these as on the original Rear Panel.

Page 48

5.08 Right Side Internal Parts Replacement

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

5. Release the hose from the Adapter Fitting on the output side of the Solenoid Assembly.

6. Install the replacement Pressure Switch/Solenoid Assembly by reversing steps 2-5. Once installed, the Solenoid Assembly should fit securely on the Heatsink Shroud. It should not be moveable.

WARNING

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

A. Pressure Switch/Solenoid Assembly

Replacement

The Pressure Switch and Solenoid Valve are one Assembly. Disconnect primary input power and bleed down the system.

1. Remove the cover per subsection 5.04-A.

2. Disconnect the following wires:

a. Wires #10 and #11 from the Pressure Switch

Assembly.

b. Wires #8 and #9 from the Solenoid Assembly.

3. Push the clip on the front of the Heatsink Shroud to the left to release the Solenoid Assembly. Dislodge the Assembly from underneath the clip on the top of the Heatsink Shroud.

7. Re-install the power supply cover.

B. Pilot PC Board Assembly Replacement

Follow the antistatic procedures in subsection 5.02.

1. Remove the power supply cover per subsection

5.04-A.

2. Label, then disconnect the wiring connections to the Pilot PC Board Assembly.

a. J28 Connector

b. Wire connectors to terminals E58 and E62.

3. Remove the bolts securing the PC Board to the standoffs.

4. Slide the PC Board upward to release it from its bottom supports.

5. Install the replacement Pilot PC Board Assembly by reversing the above steps.

6. Reinstall the Power Supply cover.

C. Fan Replacement (M1, M2)

1. Remove the cover per subsection 5.04-A.

Dislodge Solenoid

Push Clip

to the left to

release Solenoid

Assembly

Art # A-03705

Assembly

Heatsink Shroud

4. Release the hose from the Adapter Fitting on the input side of the Solenoid Assembly. Hold a wrench or similar tool against the locking ring on the Fitting, then pull on the hose to release it.

2. Label, then carefully remove the wiring connectors from the terminals on the Fans.

3. Disconnect the Work Cable from terminal E61 on the Power Output Board.

4. Remove one bolt from the Front Panel of the Power Supply, near the Control Panel. Pull the Front Panel slightly away from the Power Supply.

5. Remove one nut from a stud at the bottom of the Fan Assembly Panel.

6. Lift the Fan Assembly Panel and pull it out of the Power Supply.

REPLACEMENT PROCEDURES 5-8 Manual 0-2957

Page 49

7. Remove two bolts per Fan. Set the Fan(s) aside.

D. Output Diode PC Board Replacement

8. Install the replacement Fan Assembly as follows:

a. Fasten Fan(s) in position with the wiring con-

nectors at the bottom of the Fan(s).

NOTE

Only two screws are needed to attach the Fan to the Fan Panel. They can be installed in any two holes provided they are opposite each other. For grounding purposes, one of those screws must be installed with a star washer.

b. Place the Fan Assembly Panel in position in

the Power Supply.

1. The inner edge of the Panel has tabs that engage slots in the center chassis. Ensure that these tabs fully engage in the chassis.

2. Press the Panel downward. Press the bottom flange fully against the bottom panel of the Power Supply.

3. Ensure that the hole in the bottom flange of the Fan Assembly Panel engages the mounting stud.

c. Replace nut on the bottom mounting stud.

Follow the antistatic procedures in subsection 5.02.

1. Remove cover per subsection 5.04-A.

2. Locate the Output Diode PCB(s) located within the Output Power PC Board on the right side of the power supply.

3. Carefully remove all wire connections to the Output Diode Board(s).

4. Remove screw(s) securing Output Diode PC Board(s) to the Heatsink and remove board(s) from the Power Supply.

5. Use isopropyl alcohol and a clean rag to clean the heatsink. Do not scratch or abrade the heatsink.

6. Apply the thermal pad provided with the replacement PCB to the heatsink. Secure in place with small pieces of masking tape. The tape must cover no more than 1/4" (6 mm) of the edge of the thermal pad.

Round

Output Diode or IGBT

Tape

Thermal Pad

d. Ensure that the Fan Panel's top flange is fully

against the top forward edge of the Heatsink Shroud.

e. Press the front panel of the Power Supply

against the Fan Panel, and fasten in place with the bolt removed in Step 2.

f. Secure the nut on the stud at the bottom of the

Fan Panel.

9. Re-connect the wires to the Fan Assemblies.

10. Pass the Work Cable through the hole in the bottom of the Fan Panel. Ensure that the grommet is in place in the hole.

11. Connect the Work Cable to terminal E61 on the Power Output PC Board. Secure the Work Cable Strain Relief.

12. Re-install the Power Supply Cover.

Washer

Screw

Tape

Art # A-03702

7. Use isopropyl alcohol to clean the large flat surface on the back of the component.

8. Secure replacement board as follows:

a. Position the hardware at the bottom of a re-

cess in the face of the diode. Ensure that the washer is under the head of the screw(s).

b. Torque hardware to 17 in-lb. (1.9 Nm).

NOTE

Failure to torque properly will cause component damage.

Manual 0-2957 5-9 REPLACEMENT PROCEDURES

Page 50

9. Connect wires as follows.

F. Heatsink Shroud Assembly Removal

CutMaster 81 Output Diode Connections

Output Diode A Output Diode B

From Output

Diode A

Terminals

E34, E 39 E37 E 34, E 39 E36 E48, E 50 E47 E 48, E 50 E45 E56, E 60 E58 E 56, E 60 E57 E53, E 54 E52 E 53, E 54 E49

To Power

Output

PCB Terminal

From Output

Diode B

Terminals

To Power

Output

PCB Terminal

E. Output Power PC Board Replacement

Follow the antistatic procedures in subsection 5.02.

1. Remove cover per subsection 5.04-A.

2. Locate the Power Output PC Board, mounted to the Heatsink Shroud.

3. Carefully remove all wire connections to the Output Diodes.

4. Straighten the Output Diode wires to be perpendicular to the Output Power PC Board.

5. Label, then disconnect all other wire connections to the Output Power PC Board. Refer to Appendix 10 for output power PC Board wiring details.

6. Remove the bolts at the top left and bottom right corners of the Output Power PC Board.

The Heatsink Shroud Assembly must be disengaged for access to either the Main Transformer or the Output Inductor. Follow these steps for access to either component.

1. Remove the Power Supply cover per subsection

5.04-A.

2. Release the tab on the vertical face of the Heatsink Shroud securing the Solenoid/Pressure Switch Assembly in position.

3. Remove the gas hose from the Regulator Fitting on the back panel of the Power Supply by pressing on the locking ring on the elbow fitting, while pulling on the hose.

4. Remove the Power Supply Back Panel per subsection 5.07-D.

Remove the grommets from the two holes on the right (rear) edge of the Heatsink Shroud.

5. Remove the Fan Assembly per subsection 5.08C.

6. Label and disconnect the wires connected to the Pilot PC Board.

7. Remove the hardware securing the Pilot PC Board in place. Pull the PC Board off the center chassis.

8. Label and disconnect wires No. 45, 47, 49, and 52 from the Power Output PC Board.

9. Disconnect the wires from the Output Inductor to terminal E43 on the Power Output PC Board.

Screw Locations

Art # A-03166

7. Lift the Output Power PC Board off its supports, and set aside.

8. Install the replacement Output Power PC Board by reversing the above steps.

9. Note that the output power PC Board includes a jumper wire between studs E58 and E57. Refer to Appendix 10 for output power PC Board wiring details.

Disconnect the torch receptacle ground wire connected to the center chassis.

10. Remove nuts on two studs at the top corners of the Heatsink Shroud, and nuts on two studs on the bottom flange of the Heatsink Shroud.

12. Remove the Heatsink Shroud as follows:

a. Use the open left end of the Heatsink Shroud

and the Pressure Switch/Solenoid opening as handles.

b. Pull the Heatsink Shroud away from the cen-

ter chassis, and then up. It may be necessary to pry the top and bottom flanges of the Heatsink Shroud slightly to release them from their mounting studs. Movement will be limited by the wiring harness.

REPLACEMENT PROCEDURES 5-10 Manual 0-2957

Page 51

G. Main Transformer Removal and

Replacement

1. Disengage the Heatsink Shroud per Paragraph H.

2. Disconnect wires #27 and 32, connected to terminals E27 and E32 on the Main Power PC Board. Pull these wires through the hole in the center chassis.

3. Remove the transformer.

a. Lift the Main Transformer slightly. Swing its

left edge away from the center chassis. Pull its right edge away from the center chassis.

b. Lift it out of the Power Supply through the

opening at the rear of the Power Supply.

4. Position the replacement Main Transformer behind the Heatsink Shroud Assembly. Position its wires at the right edge (as you face it) of the transformer.

5. Install the replacement transformer as follows:

a. Pass the tabs on the right edge of the base of

the transformer into slots in the center chassis of the Power Supply.

b. Swing the transformer against the chassis, and

pass the tabs on the left edge of the base into slots in the chassis. Press the transformer downward to lock it into position.

c. Check for proper installation; the transformer

should remain securely in place.

b. Lift out the Inductor through the opening at the

rear of the Power Supply. It may be necessary to lift the Main Transformer slightly to create room for the Inductor to pass through the rear opening.

5. Install the replacement Inductor.

a. Put the replacement Inductor in place, with the

wires oriented the same way as the original Inductor.

b. Secure the Inductor in place with hex nuts at

opposite corners of the Inductor base.

6. Reconnect the wires to the thermal switch on the Output Inductor.

7. Replace the Heatsink Shroud per paragraph I.

I. Heatsink Shroud Assembly Replacement

1. Pass transformer wires #45 and 49 through the upper hole in the right (rear) edge of the Heatsink Shroud. Pass transformer wires #47 and 52 through the lower hole.

2. Route wires as follows:

a. Pass the red wires from the output inductor

through the upper hole in the right (rear) edge of the Heatsink Shroud.

b. Pass the black wires from the output inductor

through the lower hole in the right (rear) edge of the Heatsink Shroud. Refer to Appendix 11, Power Output Board Layout.

6. Pass wires #27 and 32 through the hole in the center of the main chassis. Connect wire #27 to terminal E27 and wire #32 to terminal E32 on the Main Power PC Board.

7. Replace the Heatsink Shroud Assembly per subsection I.

H. Output Inductor Assembly Removal and

Replacement

1. Disengage the Heatsink Shroud per paragraph H.

2. Disconnect the wires to the thermal switch on the Output Inductor.

3. Remove hex nuts at the left forward and right rear corners of the Inductor base.

4. Remove the Inductor as follows:

a. Note the position of the wires leading from

the Inductor.

c. Pass the wires from the temperature switch

on the Output Inductor through the upper hole in the Shroud.

3. Re-install the Heatsink Shroud as follows:

a. Lift the Heatsink Shroud (Assembly) into po-

sition. Studs on the Power Supply base pass through holes in the bottom flange of the Shroud.

b. Swing the top edge of the Shroud Assembly

into place. Studs on the Center Chassis of the Power Supply pass through holes in the top flanges of the Shroud.

c. Ensure that the rubber feet on the Main Trans-

former engage holes in the Shroud.

Manual 0-2957 5-11 REPLACEMENT PROCEDURES

Page 52

d. Put hex nuts on the studs. Tighten the nuts on

the right (rear) top and bottom studs. Leave the nuts on the left (forward) studs loose temporarily.

4. Put the Fan Assembly in place per subsection

5.08-C. Reconnect the work cable to terminal E61 on the Power Output PC Board.

5. Tighten the nuts securing the left edge of the Heatsink Shroud Assembly. The stud and nut on the bottom left edge fasten a wire stay to the Power Supply.

6. Replace the grommets around the wire harnesses passing through the right (rearward) edge of the Heatsink Shroud.

7. Reinstall the Pilot Board. Reconnect the wires to the Pilot Board.

Reconnect the torch receptacle ground wire to the center chassis.

9. Replace the Pressure Switch/Solenoid Assembly. This assembly fits into a slot in the top horizontal surface of the Heatsink Shroud. A notched pin holds the assembly in place.

10. Connect the gas hose between the Regulator/Filter Assembly and the Gas Pressure Switch/Solenoid Assembly.

11. Connect wiring to the Output Power PC Board. Refer to the Appendix pages for wiring layout.

12. Replace the Power Supply rear panel per subsection 5.07-D.

This concludes the replacement procedures.

REPLACEMENT PROCEDURES 5-12 Manual 0-2957

Page 53

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts lists provide a breakdown of all replaceable components. The parts lists are arranged as follows:

Section 6.03 Major External Replacement Parts

Section 6.04 Front Panel Replacement Parts

Section 6.05 Left Side Internal Component

Replacement Parts

Section 6.06 Rear Panel Replacement Parts

Section 6.07 Right Side Internal Component

Replacement Parts

Section 6.08 Options and Accessories

NOTE

Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.

B. Returns

If a product must be returned for service, contact your distributor. Materials returned without proper 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.

Manual 0-2957 6-1 PARTS LISTS

Page 54

6.03 Major External Replacement Parts

Item # Qty Description Catalog #

1 1 Cover with labels 9-7997 2 Rear Panel (provide data tag information when ordering)

1 For 208/230-Volt Power Supplies 9-8323 1 For 400-Volt, 415-Volt, 460-Volt, and 600-Volt Power Supplies 9-8322

3` 1 Tube, roll handle 9-7998

Art # A-03709

NOTE: Illustration may vary slightly from unit.

PARTS LISTS 6-2 Manual 0-2957

Page 55

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, DPST 8-3258 3 1 Run/Rapid Auto Restart / Set Switch 8-3259 4 1 Assembly, Pot/LED PCB 9-8004 5 1 Cable, Work, #6 AWG, with Clamp, 20 Ft. (6.1 m) 9-8528

Art # A-03008

NOTE: Illustration may vary slightly from unit.

Manual 0-2957 6-3 PARTS LISTS

Page 56

6.05 Left Side Internal Component Replacement Parts

Item # Qty Description Ref # Catalog #

1 1 Fuse F1

for 208/230-Volt Power Supplies 9-8588 for 400-Volt and 415-Volt Power Supplies 9-8602 for 460-Volt Power Supplies 9-8583 for 600-Volt Power Supplies 9-8638

Main Input Contactor W1

2A for 208/230-Volt Power Supplies 9-8587

2 for 400-Volt, 415-Volt 460-Volt and 600-Volt Power Supplies 9-8554

3 1 Connector PCB 9-8576

4 1 PCB Assembly, Logic Board, for Non-Mechanized units 9-7992

4 1 PCB Assembly, Logic Board, for Mechanized units 9-9440

5 1 PCB Assembly Kit, IGBT Circuit

for 208/230-Volt, 400-Volt, 415-Volt and 460-Volt Power Supplies 9-8578

IGBT PCB Round Thermal Pad

for 600-Volt Power Supplies 9-8646

IGBT PCB Round Thermal Pad

6 1 PCB Assembly Kit, Input Diode 9-7088

Input Diode PCB Rectangular Thermal Pad

7 1 PCB Assembly, Main Power

for 208/230-Volt Power Supplies 9-7986 for 400-Volt Power Supplies 9-7990 for 415-VoltPower Supplies 9-8669 for 460-Volt Power Supplies 9-7989 for 600-Volt Power Supplies 9-7991

8 1 EMI Filter Kit (CE Power Supplies only) 9-7667

PARTS LISTS 6-4 Manual 0-2957

Page 57

NOTE: Illustration may vary slightly from unit.

Art # A-03717

Manual 0-2957 6-5 PARTS LISTS

Page 58

6.06 Rear Panel Replacement Parts

Item # Qty Description Ref. Catalog #

1 1 Assembly, Filter/Regulator 9-7514 2 1 Regulator/Filter Replacement Element 9-4414 3 1 Regulator Mounting Bracket 9-7589 4 Input Power Cable

1 for 208/230-Volt Units 9-8596 1 for 400-Volt Three-Phase units 9-8562 1 for 400-Volt and 415-Volt CE units 9-8553 1 for 460-Volt Three-Phase units 9-8593

1 for 600-Volt Three-Phase units 9-8593 5 1 Mounting Nut 9-5804 6 1 Pressure Gauge 9-1045

Art # A-03005

NOTE: Illustration may vary slightly from unit.

PARTS LISTS 6-6 Manual 0-2957

Page 59

6.07 Right Side Internal Component Replacement Parts

Item # Qty Description Ref #. Catalog #

1 1 Assembly, Pressure Switch/Solenoid Sol1, Ps1 9-8329 2 1 Assembly, Pilot Board 9-8337 3 1 Fan, 220V, 115 CFM 9-7687 4 1 Assembly, Main Transformer T5

for 208/230-Volt units 9-8589 for 400 Volt and 415-Volt units 9-8603 for 460-Volt units 9-8584

for 600-Volt units 9-8635 5 1 Assembly, Output Inductor L1 9-8591 6 1 Assembly, Output Power PCB 9-7988 7 1 Assembly, Output Diode PCB 9-8580

1 Round Thermal Pad

IGBT Heatsink

Fan Shroud

Heatsink Shroud

Output Diode Heatsink

Work Cable

NOTE: Illustration may vary slightly from unit.

Manual 0-2957 6-7 PARTS LISTS

Art # A-03718

Page 60

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 9-7535 1 Dual Stage Air Filter Assembly 9-7527 1 Replacement First Stage Cartridge 9-1021 1 Replacement Second Stage Cartridge 9-1022

Not Shown: 1 Extended Work Cable - 50 ft (15.2 M) 9-8529 1 Wheel Kit 9-8331 1 Nylon Canvas Power Supply Dust Cover 9-7072

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

(Cat. No. 9-7743)

Cover

Barbed

Fitting

Single-Stage Filter Kit Two-Stage Filter Kit

Assembled Filter

Art # A-02476

First & Second Stage Cartridges (as marked)

Art # A-02942

PARTS LISTS 6-8 Manual 0-2957

Page 61

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

Manual 0-2957 6-9 PARTS LISTS

Page 62

This Page Left Blank

PARTS LISTS 6-10 Manual 0-2957

Page 63

APPENDIX 1: INPUT WIRING REQUIREMENTS

CutMaster 81 Input Wiri ng Requirements

Input Power Input Current Input Suggested Sizes (See Notes)

Voltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (Canada)

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

208 50/60 11.8 57 60 6 6 230 50/60 11.8 52 60 6 6 400 50/60 11.1 16 20 10 10

4606011.727301010

4606010.816201212

6006010.510151212

Line Voltages with Suggested Circui t Protecti on and Wire Sizes

Based on National El ectri c Code and Canadian Electrical Code

CE CutM aster 81 Input Wi ring S pecifications

Input Suggested Siz e s (Se e Notes)

Vo ltage Frequ en c y 3-Ph 3-P h F use (Amps)

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

400/415 50 11.1 16 20 4

Line Voltages with Sugges t ed Circ ui t P rot ection and Wire S izes

Bas ed on Nati onal E l ec tric Code and Canadian Elec tric Code

Pow er Input Current Input

Wire (mm

)

NOTES

The table above is based on the following output current and voltage: 125VDC @ 40A

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.

Cable size is de-rated based on the Duty Cycle of the equipment.

The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations refer to local or national codes.

Cable conductor temperature used is 167° F (75° C).

An energy limiting fuse UL Class RK-1 (examples: BUSS LPS/LPN-RK or Gould-Shawmut AZK-A6K) should be used to minimize damage to Plasma Cutting, Welding or power distribution equipment.

NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.

Manual 0-2957 A-1 APPENDIX

Page 64

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.

ACTION:

Protect eyes and activate torch.

RESULT:

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.

PILOT ARC

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:

Torch moved away from work (while

still activated).

RESULT:

Main arc stops.

Pilot arc automatically

restarts.

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.

APPENDIX A-2 Manual 0-2957

ACTION:

ON / OFF switch

to OFF

RESULT:

All indicators off.

Power supply fan(s) shuts off.

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

Page 65

APPENDIX 3: LOGIC PC BOARD LAYOUT

TP4

TP2

TP1

TP3

D13

TP6

D33

P1-7

P1-9

TP9

TP10

TP11

TP5

Logic Board Signals

P1-1 +12vdcfrom Main Power PCB P1-2 +12vdcfrom Main PCB P1-3 DC Com P1-4 DC Com P1-5 MC1 ON signal P1-6 Tip Sense P1-7 RUN/SET Signal Logic Low for SET P1-8 Logic Low = PS1 Pressure Switch

closed = Pressure OK P1-9 Logic Low = TS1 Closed = OVERTEMP P1-10 Logic Low = CSR P1-11 Logic Low = Gas ON P1-12 Logic Low = DC OK P1-13 Logic Low = OVTEMP P1-14 Logic Low = AC OK P1-15 Logic Low = Torch Switch P1-16 Logic Low = Torch Switch Return P1-17 Logic Low = +12vdc P1-18 Logic Low = Pot High P1-19 Logic Low = Pot High P1-20 Pot Low P1-21 Gate Drive B Return P1-22 Gate Drive B P1-23 Gate Drive A Return P1-24 Gate Drive A P1-25 - Out Sense P1-26 Current Sense

D25

TP8

P1-27 Current Sense P1-28 Current Sense Return P1-29 Current Sense Return P1-30 DC Com P1-31 DC Com P1-32 Not Used P1-33 I Sense P1-34 Not Used P1-35 Not Used P1-36 TipVolts

INDICATORS: D13 INV ON D25 DRAG ON D33 SWITCH ON

TEST POINTS: TP-1 Common TP-2 Current Demand Signal TP-3 Converter Enable

TP-4 CSR (Logic Low) TP-5 Not used TP-6 Fault (Logic Low) TP-7 DC OK (Logic Low) TP-8 Tip Sense TP-9 Current Sense TP-10 Gate Drive A TP-11 Gate Drive B

TP7

Art # A-03654

Manual 0-2957 A-3 APPENDIX

Page 66

APPENDIX 4: MAIN POWER PC BOARD LAYOUT

J16

J17

J15

J11

E15

J25

E10

E20

E22

TP4

FUSE

INPUT DIODE

TP1

J23

J24

J34

J32

J29

J33

J18

J27

J43

E32

J26

E27

E30

Art # A-03651

IGBT A

Main Power PC Board Signals

J11-1 L1 Input J11-4 L3 Input

J15-1 Fan (M1) J15-2 Fan (M1) J15-3 Not used J15-4 Not used J15-5 Fan (M2) J15-6 Fan (M2)

J16-1 Not used J16-2 Not used

J17-1 Not used J17-2 Not used

E33

J30

J31

E23

J18-1 Not used J18-2 Not used J18-3 28 VAC B J18-4 28 VAC A J18-5 On-Off Switch J18-6 On-Off Switch J18-7 Run-Set Switch J18-8 Run-Set Switch

J23-1 Not used J23-2 Not used J23-3 Not used

J24-1 Gas Solenoid (SOL1) J24-2 Gas Solenoid (SOL1) J24-3 Pressure Switch (PS1) J24-4 Pressure Switch (PS1) J24-5 Main Contactor (W1) J24-6 Main Contactor (W1) J24-7 Not used J24-8 Not used

IGBT B

APPENDIX A-4 Manual 0-2957

Page 67

J25-1 Gate Drive J25-2 Gate Drive

J26-1 Gate Drive J26-2 Gate Drive J27-1 Pot High J27-2 Pot Wiper J27-3 Pot Low J27-4 +12V J27-5 AC J27-6 Gas J27-7 Overtemp J27-8 DC

J29-1 IGBT Heatsink Temp J29-2 IGBT Heatsink Temp J29-3 Jumper J29-4 Jumper

J30-1 Gate Drive J30-2 Gate Drive

J31-1 Gate Drive J31-2 Gate Drive

J32-1 Inductor Temp Switch J32-2 Inductor Temp Switch

J33-1 - Out Sense J33-2 DC Com J33-3 Tip Sense J33-4 + 12 vdc J33-5 CSR J33-6 I Sense J33-7 Not used J33-8 Tip volts J34-1 PIP Return J34-2 PIP J34-3 Not used J34-4 Not used J34-5 Torch Switch Return J34-6 Torch Switch

J43-1 + 12 vdc to Logic PCB J43-2 + 12 vdc to Logic PCB J43-3 DC Com J43-4 DC Com J43-5 MC1 On J43-6 Tip Sense J43-7 Run / Set J43-8 Pressure Good J43-9 Overtemp J43-10 CSR J43-11 Gas on J43-12 DC OK J43-13 OVTEMP J43-14 AC OK J43-15 Torch Switch J43-16 Torch Switch Return J43-17 + 12 vdc J43-18 POT High J43-19 POT Wiper J43-20 POT Low J43-21 Gate Drive B Return J43-22 Gate Drive B J43-23 Gate Drive A Return J43-24 Gate Drive A J43-25 - Out Sense J43-26 Current Sense J43-27 Current Sense J43-28 Current Sense Return J43-29 Current Sense Return J43-30 DC Com J43-31 DC Com J43-32 Not Used J43-33 I Sense J43-34 Not Used J43-35 Not Used J43-36 Tip Volts

TP1 Ground TP4 +12 vdc

Manual 0-2957 A-5 APPENDIX

Page 68

APPENDIX 5A: MAIN PC BOARD WIRING LAYOUT -

208/230-Volt Units

To Press Switch/Solenoid/Contactor

To Chassis Ground

Copper Strap

LT 1

INPUT DIODE

To Main Input Contactor

Fuse

Test Connector

To Fans

Secondary Transformer

To Inductor Temp Sensor

To Heat Sink Temp Sensor

#27

J30

To To r ch Connector

#32

J31

To Power Output Board

To On/Off and Run/Rapid Restart Set Switches

To Auto Interface Board J1-5*

To Auto Interface Board J1-6*

To POT/LED PCB

(or to

Optional Remote

Current Control )*

To Logic Board via Connector

To Main Transformer

#33

#78

* Automation Interface Board is not installed in all units.

To Input Contactor

APPENDIX A-6 Manual 0-2957

To Input Contactor

Art # A-03652

Heat Sink Temp Sensor

* If installed in conjuction with Automation Interface PC Board

Page 69

APPENDIX 5B: MAIN PC BOARD WIRING LAYOUT -

400-Volt, 415-Volt 460-Volt, and 600-Volt Units

To Press Switch/Solenoid/Contactor

To Chassis Ground

Fuse

LT 1

To Main Input Contactor

INPUT DIODE

Te s t Connector

To Fans

Secondary Transformer

To Inductor Temp Sensor

To Heat Sink

Temp Sensor To To r ch Connector

#32

#27

J30

J31

To Power Output Board

To On/Off and Run/Rapid Restart Set Switches

To Auto Interface Board J1-5*

To Auto Interface Board J1-6*

To POT/LED PCB

(or to

Optional Remote

Current Control )*

To Logic Board via Connector

To Main Transformer

* Automation Interface Board is not installed in all units.

To Input Contactor

Manual 0-2957 A-7 APPENDIX

Art # A-03653

Heat Sink Temp Sensor

* If installed in conjuction with Automation Interface PC Board

Page 70

APPENDIX 6: LED/POT PC BOARD LAYOUT

J14

A-03712

Pot/LED PC Board Signals

J14-1 from Main PC Board (J27-1) Pot High J14-2 Main PC Board (J27-2) Pot Wiper J14-3 from Main PC Board (J27-3) Pot Low J14-4 12vdc (J27-4) J14-5 Logic Low Signal for AC OK Indicator from Logic PC Board (J27-5) J14-6 Logic Low Signal for GAS Indicator from Logic PC Board (J27-6) J14-7 Logic Low Signal for TEMP Indicator from Logic PC Board (J27-7) J14-8 Logic Low Signal for DC Indicator from Logic PC Board (J27-8)

D4 Front Panel AC Indicator D5 Front Panel TEMP Indicator D6 Front Panel GAS Indicator D7 Front Panel DC Indicator

APPENDIX A-8 Manual 0-2957

Page 71

APPENDIX 7: INPUT DIODE PC BOARD LAYOUT

E14

E18

E16

E13

19x1811

Art # A-03703

Manual 0-2957 A-9 APPENDIX

Page 72

APPENDIX 8: IGBT CIRCUIT PC BOARD LAYOUT

E11A

J3A

TP1

E9A

E12A

E17A

E21A

E19A

J7A

TP2

J3B

TP1

E11B

E9B

E12B

E17B

E21B

E19B

J7B

TP2

A-03704

APPENDIX A-10 Manual 0-2957

Page 73

APPENDIX 9: OUTPUT DIODE PC BOARD LAYOUT

E34

E39

E60

E56

Output Diode A

E48

E50

E54

E53

E34

E39

E60

E56

Output Diode B

E48

E50

E54

E53

A-03152

Manual 0-2957 A-11 APPENDIX

Page 74

APPENDIX 10: OUTPUT BOARD WIRING DIAGRAM

Chassis Ground

Output

Diode A

To Pilot Board

E64

To To r ch

E37

To To r ch

E35

To Pilot PCB

E62

E47

To Main PCB To Pilot PCB

J39

TP1

J40

E36

Output

Diode B

E32

To Output Inductor

E45

To Tr a ns former

E49

To Tr a ns former

E43

To Output Inductor

E58

E52

Work Cable

E61

E57

Art # A-03655

APPENDIX A-12 Manual 0-2957

Page 75

APPENDIX 11: PILOT PC BOARD LAYOUT

J28

No Receptacle

E58

E62

J28

2 - Pin

Receptacle (J1)

E58

E62

Art # A-03881

CD PC Board Signals

J28-1 +12 vdc J28-2 DC Com J28-3 Not Used J28-4 Not Used J28-5 Logic Low CSR J28-6 Not Used J28-7 Not Used J28-8 Not Used

E58 To Power Output PC Board Terminal E58 E62 To Power Output PC Board Terminal E62

NOTES

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

2. Receptacle J1 is used only in automated applications.

Manual 0-2957 A-13 APPENDIX

Page 76

APPENDIX 12: 28VAC CIRCUIT DIAGRAM

Line Voltage

SOL

1 2 5 6

A-03710

J24

Auxiliary

Transformer

J81

Fuse

primary

J11

J18

secondary

Main Power PC Board

3 4 5 6

J23 (Test)

+12vdc

ON/OFF Switch

Voltage Protection CRT/+12 Regulator

APPENDIX A-14 Manual 0-2957

Page 77

APPENDIX 13: DATA TAG INFORMATION

Type of Power Supply (Note 1)

Plasma Cutting Symbol

Input Power Symbol

Input Power Specifications (Phase, AC or DC Hertz Rating)

Model:

Date of Mfr:

1/3

Output Current Type

Rated NoLoad Voltage

Degree of Protection

Conventional Load Voltage

West Lebanon, NH USA 03784

Rated Supply Voltage (Note 2)

S/N

Duty Cycle Factor

Rated Maximum Supply Current

1max 1eff

1Ø

3Ø

Made in USA

3Ø1Ø

Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number and Production Code

Regulatory Standard Covering This Type of Power Supply

Output Range (Amperage/ Voltage)

Duty Cycle Data (Note 3)

Maximum Effective Supply Current

Manufacturer's Electrical Schematic File Number and Revision Level

NOTES:

1. Symbol shown indicates single- or three-phase AC input, static frequency converter-transformer-rectifier, DC output.

2. Indicates input voltages for this power supply. Most power supplies carry a label at the input power cord showing input voltage requirements for the power supply as built.

3. Top row: Duty cycle values. IEC duty cycle value is calculated as specified by the International ElectroTechnical Commission. TDC duty cycle value is determined under the power supply manufacturer's test procedures. Second row: Rated cutting current values. Third row: Conventional load voltage values.

4. Sections of the Data Tag may be applied to separate areas of the power supply.

Standard Symbols

Phase

Art # A-03288

Manual 0-2957 A-15 APPENDIX

Page 78

APPENDIX 14: TORCH PIN-OUT DIAGRAMS

A. Hand Torch Pin - Out Diagrams

ATC Male Connector

Negative / Plasma

4 - Green / Switch

3 - White / Switch

2- Orange / PIP

1 - Black / PIP

Pilot

Front View

8 - Open

7 - Open

6 - Open

5 - Open

B. Mechanized (Machine) Torch Pin - Out Diagrams

8 - Ground

7 - Open

6 - Open

5 - Open

ATC Female Receptacle

Front View

8 7

Pilot

Negative / Plasma

4 - Switch

4 3

2 1

3 - Switch

2 - PIP

1 - PIP

A-03701

ATC Male Connector

4- Black Pendant Connector

3 - White Pendant Connector

2 - Orange / PIP

1 - Black / PIP

Art # A-03799

Front View

4 3

UNSHIELDED MACHINE TORCH

Negative / Plasma

8 - Green Pendant Connector Ground

8 7

Pilot

7 - Green / Not Used

6 - Open

5 - White / Not Used

8 - Ground

7 - Open

6 - Open

5 - Open

ATC Female Receptacle

Front View

8 7

2 1

Pilot

Negative / Plasma

4 - Switch

4 3

3 - Switch

2 - PIP

1 - PIP

APPENDIX A-16 Manual 0-2957

Page 79

APPENDIX 15: TORCH CONNECTION DIAGRAMS

A. Hand Torch Connection Diagram

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

Torch

Head

PIP

Switch

Torch

Switch

Torch Leads

Black

Orange

Green

White

Negative / Plasma

Pilot

Male

ATC Leads

Connector

ATC Female

Receptacle

Power

Supply

To Power Supply

Circuitry

To Power Supply

Circuitry

Negative / Plasma

Pilot

Art # A-03797

B. Mechanized (Machine) Torch Connection Diagram

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

Remote Pendant Connector

Power Supply: with ATC Female Receptacle

Remote

Pendant

Connector

Torch

Head

PIP

Switch

Male

ATC Leads

Connector

Torch Leads

Black

Orange

White

Not

Used

Green

Negative / Plasma Lead

Pilot Lead

To Remote Control

Black

White

Green

ATC Female

Receptacle

Power

Supply

To Power Supply

Circuitry

To Power Supply

Circuitry

Negative / Plasma

Pilot

Art # A-03798

Manual 0-2957 A-17 APPENDIX

Page 80

APPENDIX 16A: SYSTEM SCHEMATIC, 208/230-Volt Units

208/230V 1 PHASE INPUT

ON/OFF SW

MODE SW

CURRENT ADJUST: 20 - 80 FOR CM101 20 - 60 FOR CM81

CURRENT CONTROL/ LED PCB 19X1604

IGBT HEATSINK TEMP

INDUCTOR TEMP

LOGIC ASSY 19X1913 - CM101 ASSY 19X2285 - CM101 ASSY 19X1932 - CM81 ASSY 19X2284 - CM81

INV ON

DRAG ON

SW ON

Art # A-07153

M1 FAN1

M2 FAN2

(46)

RAR OFF

(PILOT PCB)

(F9)

TIP SENSE

RUN/SET

PRESS GOOD

OVERTEMP

D13

D25

OVTEMP

D33

TORCH SW

TORCH SW RTN

POT HIGH

POT WIPER

POT LOW

GATE DRIVE B RTN

GATE DRIVE B

GATE DRIVE A RTN

GATE DRIVE A

- OUT SENSE CURRENT SENSE CURRENT SENSE

CURRENT SENSE RTN CURRENT SENSE RTN

TIP VOLTS

28VAC B 28VAC A

SW1

RUN

SW2

NTC

+12VDC

+12VDC DC COM DC COM

W1 ON

CSR

GAS ON

DC OK

AC OK

+12V

DC COM DC COM

ISENSE3233

230V

TEMP

GAS

10 11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30 31

34 35 36

SET

1 2 3 4 5 6 7 8 9

TS2

TS1

P13

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

EXTENDER ASSY 19X1775

CHASSIS GND

(4)

(5)

(7) (7)

(6) (6)

P14 P27 J27J14

(1)

(2)

(3)

(78)

E22

1 2

P11

3 4

P15 J15

1 2 3 4 5 6

P18 J18

1 2

(21)

(22)

(23)

(24)

(25)

(26)

(35)

(36)

(37)

(38)

(39)

(40)

(41)

(42)

P29

1 2 3 414

P32 J32

121 2

J12

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

J11

1 2 3 4

(6/10A 600V)

1 2

3 4 5 6

1 2 3 4 5 6 7 8

POT HIGH

POT WIPER

POT LOW

+12V

5 6

GAS

OVERTEMP

J29

2 3

J43

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

MAIN BOARD

ASSY 19X1912

E1E1

E33E33

R30

(0 ohm)

INRUSH

FAN

CONTACTOR ON

SOLENOID ON

E2E2

(FILTERING)

28VAC A 28VAC B

+12VDC

+18V

(33)

E3E3

28VAC A28VAC B

E13

E18

INPUT DIODE

ASSY 19X2073

COPPER STRAP

TO BIAS SUPPLY

F2, 0.9A, (RESETABLE)

PRESS GOOD

CURRENT SENSE

-OUT SENSE DC COM

TIP SENSE

+12VDC

I SENSE

TIP VOLTS

PIP RTN

TORCH SW RTN

TORCH SW

28VAC A

28VAC B

J26

J31

J30

J25

CSR

6 7

J34 P34

PIP

J23

GND

2 3

J24

E6 E8

E14 E16

1 2

1 2 3 4 5

1 2 3 4 5 66

1 2 3 4 5 6 7 8

1 2

E5 E6

P33J33

1 2 3 4 5 6 7 8

1 2 3 4 5

TEST CONN

P24

1 2 3 4 5 6 7 8

E15

E20

E23

E30

P26

P31

P30

P25

(TS2)

(TS1)

E10

E27

E32

(70) (71) (72) (73) (74) (75)

(77)

ATC CONNECTION CONFIGURATION

(STANDARD) (78) (79)

(80) (81)

(8)

(9) (10) (11) (12) (13)

MAIN

MAIN TRANSFORMER

PRI

PIP

575 7 4

TORCH

ATC MALE CONNECTOR

ATC RECEIVER

SOL1

GAS SOLENOID

PS1

CLOSED WHEN

PRESSURE OK

CONTACTOR

E12A

E17A

24 25

E19A

E21A

E12B

E17B

24 25

E19B

E21B

ASSY 19X1756

SEC

SOL2

11 15

PRI

SEC

FACTORY INSTALLED OPTIONAL TORCH MOUNTED GAS SOLENOID

PRESSURE SWITCH

WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED, SOL1 IS POWERED BY T6 ONLY ,SOL2 POWERED BY P24-1,-2

12231314

IGBT BOARD

ASSY 19X1756

12231314

IGBT BOARD

J39P39

GATE DRIVE

2456

GATE DRIVE

24567

E52 E47

J7B

J3A

J7A

J3B

212

P3A

E9A

E11A

P7A

P3B

E9B

E11B

P7B

APPENDIX A-18 Manual 0-2957

Page 81

COMP DESCRIPTION LOCATION

FUSE, 6/10A 600V KTK

FUSE, 0.9A, RESETABLE

OUTPUT INDUCTOR

FAN, 4.5" 220VAC

PS1

PRESSURE SWITCH

SOL1

GAS SOLENOID

SW1

SWITCH, ON/OFF

SW2

SWITCH, RUN/SET/RAR

MAIN TRANSFORMER

TS1

TEMP. SENSOR, IGBT HEATSINK

TS2

TEMP. SENSOR, INDUCTOR

MAIN CONTACTOR

NOTES: UNLESS OTHERWISE SPECIFIED -

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

D4T5

ADAPTER HARNESS USED WHEN REMOTE CURRENT CONTROL IS USED WITH AUTOMATION (REPLACES CONNECTIONS FROM J27 TO J14)

E49 E45 E35

E62

JUMPER

OUTPUT DIODE ASSEMBLY 19X1757

E50B

E48B

E53B E54B

OUTPUT DIODE ASSEMBLY 19X1757

E50A

E48A

E53A E54A

E34A

E37 E58

E39A

E56A E60A

POWER OUTPUT BOARD ASSY 19X1914

PLUGS INTO J27

ON MAIN BOARD

(LED PCB 19X1604)

TEMP

GAS

OUTPUT INDUCTOR

E43

PILOT

E34B

OPTIONAL AUTOMATION INTERFACE CONNECTIONS

+12VDC DC COM

CSR

ISENSE

J40

E63

2112 3

19X2041

OPTIONAL

AUTOMATION INTERFACE

(CSR)

CSR

(51)

DC COMMON

(52)

+12VDC

(TS2)

TORCH SW -

(TS1)

TORCH SW +

(NEG)

(E64)

(E35)

(E62)

(C1)

(MODE SW)

RAR OFF

P40

(14)

(15)

(17)

5 6

6 7

(18)

THRU SCREW TERMINAL

AA AB AC AD AE

Last Modified:

(E58)

E58

(52)

(51)

1 2

(46)

J28

(REL) DLL 05/07/03

ECO 101136

ECO 101429 HAS 06/09/04 ECO 101614

ECO B028 RS

ECO B016 RWH 01/27/06

Friday, January 27, 2006

J14 P14

1 2 3 4 5 6 7 8

E32

E64

E36 E57

E39B

E56B E60B

1 2 3 4 5 6 7 8

CURRENT SENSE

(47) (48) (49)

(CSR) (NEG)

CSR Vo

CHASSIS GND

NOMMOC CDNOMMOC CD

E3 E1

1 2 3 4 5 6 7 8

E61

ALTERNATE 20-PIN HEADER

20-POSITION TERMINAL STRIP

TORCH SWITCH

4 5 6

OK TO MOVE 7 8 9

DIVIDED OUTPUT

12 13 14

REMOTE CURRENT CONTROL

15 16 17

DC COMMON

C&G

(57)

(59)

(61)

(63)

E62

PILOT BOARD ASSY 19X2157

DateByRevisionsRev

HAS 02/11/04ECO 101314

HAS 03/22/05

Information Proprietary to THERMAL DYNAMICS CORPORATION.

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

01/09/06

NOTE:

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)

TITLE:

11:05:29

CM81/101 208/230V SYSTEM

CPC

HOUSING

(56)

4 3

(58)

14 12

(60)

6 5

(62)

8 9

(64)

ATC RECEIVER ATC MALE CONNECTOR

WORK

SCHEMATIC,

(+)

TORCH SWITCH

}

(-)

}

OK TO MOVE

(+)

}

SC-11

(-)

LOGIC COMMON

(+)

}

ARC VOLTS (C&G)

(-)

T O R C H

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

Assy No:

Chk: App:

PCB No:

SupersedesScale

Date:

05/07/03

Drawn: References

D.Lilja

Sheet

DWG No:

Size

DWG No:

Size

DWG No:

Size

42X1136

Art # A-07153

Manual 0-2957 A-19 APPENDIX

Page 82

APPENDIX 16B: SYSTEM SCHEMATIC,

400-Volt, 415-Volt and 460-Volt Units

208/230V 1 PHASE

INPUT

400V 3 PHASE INPUT

400V 'CE' VERSION INCLUDES IN-LINE

EMC FILTER

ON/OFF SW

MODE SW

CURRENT ADJUST: 20 - 80 FOR CM101 20 - 60 FOR CM81

CURRENT CONTROL/ LED PCB 19X1604

IGBT HEATSINK TEMP

INDUCTOR TEMP

LOGIC ASSY 19X1913 - CM101 ASSY 19X2285 - CM101 ASSY 19X1932 - CM81 ASSY 19X2284 - CM81

INV ON

DRAG ON

SW ON

Art # A-07152

415/400V

/460V 3 PHASE INPUT

M1 FAN1

M2 FAN2

(46)

RAR OFF

(PILOT PCB)

(F9)

+12VDC

+12VDC DC COM DC COM

TIP SENSE

RUN/SET

PRESS GOOD

OVERTEMP

D13

GAS ON

D25

OVTEMP

D33

TORCH SW

TORCH SW RTN

POT HIGH

POT WIPER

POT LOW

GATE DRIVE B RTN

GATE DRIVE B

GATE DRIVE A RTN

GATE DRIVE A

- OUT SENSE CURRENT SENSE CURRENT SENSE

CURRENT SENSE RTN CURRENT SENSE RTN

DC COM DC COM

ARC HOLD

ISENSE3233

TIP VOLTS

RUN

W1 ON

DC OK

AC OK

+12V

230V

28VAC B 28VAC A

SW1

SW2

NTC

CSR

SET

TEMP

GAS

TS2

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

34 35 36

TS1

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

J14

1 2 3 4 5 6 7 8

P13

1 2 3 4 5 6 7 8 9

EXTENDER ASSY 19X1775

CHASSIS GND

E22

P11 J11

(4)

(5)

(7) (7)

(6) (6)

P18

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

P14 J27P27

(35)

(36)

(37)

(38)

(39)

(40)

(41)

(42)

P29

P32 J32

J12 J43

(1)

(2)

(3)

E33

R29 (415/460/600V)

R78 (400V)

R30 (208/230V)

J15P15

2 3

3 4

5 6

6 7

7 8

J29

3 414

121 2

12 13

13 14

20 21

SEE TABLE 1 FOR F1, R29,R30 & R78

J18

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

CONTACTOR ON

SOLENOID ON

MAIN BOARD ASSY 19X1930 (400V) ASSY 19X2228 (415V) ASSY 19X1929 (460V)

+12VDC

INRUSH

FAN

(FILTERING)

28VAC A 28VAC B

+18V

E3E2E1

E13

E18

28VAC A28VAC B

TO BIAS SUPPLY

PRESS GOOD

INPUT DIODE

ASSY 19X2073

ARC HOLD

CURRENT

SENSE

TORCH SW RTN

F2, 0.9A, (RESETABLE)

J26

J31

J30

J25

28VAC A

28VAC B

-OUT SENSE DC COM

TIP SENSE

+12VDC

CSR

I SENSE

TIP VOLTS

PIP RTN

TORCH SW

28VAC A

GND

28VAC B

1 2

J33 P33

2 3

5 6 7

J34

PIP

J23

1 2 3

J24

E6 E8

E14 E16

1 2

E32

1 2 3 4 5 6 7 8

P34

1 2 3 4 5

TEST CONN

P24

1 2 3 4 5 6 7 8

E15

E20

E23

E30

E34 E36 E35 E5 E6

E10

E27

(78) (79)

(12) (13)

P26

P31

P30

P25

(80) (81)

(8)

(9) (10) (11)

(TS2)

(TS1)

(70) (71) (72) (73) (74) (75)

(77)

ATC CONNECTION CONFIGURATION

(STANDARD)

575 7 4

4 3

3 8

MAIN CONTACTOR

E12A

E17A

E19A

E21A

E12B

E17B

E19B

E21B

MAIN TRANSFORMER

PRI

SEC

PRI

SEC

SOL2

PIP

TORCH SW

ATC MALE CONNECTOR

ATC RECEIVER

SOL1

GAS SOLENOID

PS1

FACTORY INSTALLED OPTIONAL TORCH MOUNTED GAS SOLENOID

PRESSURE SWITCH

CLOSED WHEN PRESSURE OK

WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED, SOL1 IS POWERED BY T6 ONLY ,SOL2 POWERED BY P24-1,-2

24 25

11 15

PRI

SEC

12231314

IGBT BOARD

ASSY 19X1756

12231314

IGBT BOARD ASSY 19X1756

P39

GATE

J3A

E52

J3B

J7B

J7A

P3A

E9A

E11A

P7A

P3B

E9B

E11B

P7B

E47

DRIVE

GATE DRIVE

24567

GATE DRIVE

24567

J39

APPENDIX A-20 Manual 0-2957

Page 83

TABLE 1

19X1930 19X1929

19X2228

400V 460V

R78

R29

R30

ZERO-OHM

115X465-2

X X X X X

4/10, 500V

21X186

415V

X X X X X

ZERO-OHM 115X465-2

X X X X X

4/10, 500V

21X186

X X X X X

ZERO-OHM 115X465-2

1/4A, 500V

21X183

COMP DESCRIPTION LOCATION

SEE CHART 1

0.9A, (RESETABLE)

OUTPUT INDUCTOR

FAN, 4.5" 220VAC

PS1

PRESSURE SWITCH

SOL1

X X X X XX X X X X

GAS SOLENOID

SWITCH, ON/OFF

SW1

SWITCH, RUN/SET/RAR

SW2

MAIN TRANSFORMER

TS1

TEMP. SENSOR, IGBT HEATSINK

TS2

TEMP. SENSOR, INDUCTOR

MAIN CONTACTOR

NOTES: UNLESS OTHERWISE SPECIFIED -

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

E65E65

E50A E48A

E53A E54A

OUTPUT DIODE ASSEMBLY 19X1757

E34A

E39A

E56A E60A

POWER OUTPUT BOARD ASSY 19X1914

E49 E45

TIP

E58E37

PLUGS INTO J27

ON MAIN BOARD

(LED PCB 19X1604)

ADAPTER HARNESS USED

WHEN REMOTE CURRENT CONTROL IS USED WITH

AUTOMATION (REPLACES CONNECTIONS FROM J27 TO J14)

OUTPUT INDUCTOR

E35

E62

PILOT

E43

JUMPER

OUTPUT DIODE ASSEMBLY 19X1757

E50B

E48B

E53B

E54B

E34B

OPTIONAL AUTOMATION INTERFACE CONNECTIONS

+12VDC

CSR

ISENSE

J40

E63

2112 3

19X2041

OPTIONAL AUTOMATION INTERFACE

(CSR)

CSR

(51)

DC COMMON

(52)

+12VDC

(TIP)

TIP

(TS2)

TORCH SW -

(TS1)

TORCH SW +

(NEG)

ARC HOLD

(E64)

(E35)

(E62)

(C1)

(MODE SW)

RAR OFF

P40

(14)

(15)

(17)

5 6

6 7

(18)

CHASSIS GND THRU SCREW TERMINAL

ECO B028

ECO B016

Last Modified:

13 12

11 10

9 8

7 6

4 3

(E58)

E58

(52)

(51)

1 2

(46)

J28

Friday, January 27, 2006

J14 P14

TEMP

GAS

E32

E64

E36 E57

E39B

E56B E60B

1 2 3 4 5 6 7 8

NOMMOC CDNOMMOC CD

(47) (48)

(49)

(CSR) (NEG)

E3 E1

CSR Vo

DC COM

1 2

3 4

6 7

7 8

E61

CURRENT SENSE

ALTERNATE 20-PIN HEADER

2 3

4 5 6 7 8 9

10 11

12 13 14 15 16

DC COMMON

17 18

19 20

21 22 23 24 25 26

E62

PILOT BOARD ASSY 19X2157

DateByRevisionsRev

01/09/06RS

01/27/06

RWH

Information Proprietary to THERMAL DYNAMICS CORPORATION.

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

NOTE:

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)

TITLE:

CM81/101 400/415/460V SYSTEM

20-POSITION TERMINAL STRIP

TORCH SWITCH

OK TO MOVE

DIVIDED OUTPUT

REMOTE CURRENT CONTROL

C&G

}

OHMIC SENSE RELAY ARC HOLD

ARC HOLD RETURN

CPC HOUSING

(56)

(57)

(58)

(59)

(60)

(61)

(62)

(63)

(64)

(+)

TORCH SWITCH

}

(-)

}

OK TO MOVE

(+)

SC-11

}

(-)

LOGIC COMMON

(+)

ARC VOLTS (C&G)

}

(-)

ATC RECEIVER ATC MALE CONNECTOR

T O R C H

WORK

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

SCHEMATIC,

PCB No:

Assy No:

Date:

Drawn: References

Chk: App:

Size

Art # A-07152

D.Lilja

05/07/03

DWG No:

SupersedesScale

Sheet

42X1135

Manual 0-2957 A-21 APPENDIX

Page 84

APPENDIX 16C: APPENDIX 16C: SYSTEM SCHEMATIC,

600-Volt Units

600VAC 3 PHASE

INPUT

CURRENT ADJUST: 20 - 80 FOR CM101 20 - 60 FOR CM81

LOGIC ASSY 19X1913 - CM101 ASSY 19X2285 - CM101 ASSY 19X1932 - CM81 ASSY 19X2284 - CM81

DRAG ON

SW ON

Art # A-07151

M1 FAN1

M2 FAN2

ON/OFF SW

MODE SW

RAR OFF

(PILOT PCB)

(F9)

CURRENT

CONTROL/

LED PCB 19X1604

IGBT HEATSINK TEMP

INDUCTOR TEMP

INV ON

D13

D25

D33

GATE DRIVE B RTN

GATE DRIVE A RTN

CURRENT SENSE

CURRENT SENSE CURRENT SENSE RTN CURRENT SENSE RTN

28VAC B 28VAC A

RUN

(46)

+12VDC

+12VDC DC COM DC COM

W1 ON

TIP SENSE

RUN/SET

PRESS GOOD

OVERTEMP

CSR

GAS ON

DC OK

OVTEMP

AC OK

TORCH SW

TORCH SW RTN

+12V

POT HIGH

POT WIPER

POT LOW

GATE DRIVE B

GATE DRIVE A

- OUT SENSE

DC COM DC COM

ISENSE3233

TIP VOLTS

(1)

(2)

(3)

(FILTERING)

28VAC A 28VAC B

+12VDC

+18V

E3E2E1

28VAC A28VAC B

SW1

SW2

NTC

230V

SET

TEMP

GAS

TS1

J14

CHASSIS GND

(4)

(5)

(7) (7)

(6) (6)

P14 P27

E22

P11

141 2 3

1 2 3 4 5 6

P18 J18

1 2

(21)

(22)

(23)

(24)

(25)

(26)

(35)

(36)

(37)

(38)

(39)

(40)

(41)

(42)

P29 J29

1 2 3 414

P32

J11

2 3 4

J15P15

1 2 3 4 5 6

1 2 3 4 5 6 7 8

J27

POT HIGH

POT WIPER

POT LOW

+12V

GAS

OVERTEMP

7 8

2 3

J32

E33

R29

(0 ohm)

(3/10A 600V)

INRUSH

FAN

TS2

P13

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

EXTENDER ASSY 19X1775

J12 J43

12 13

13 14

20 21

CONTACTOR ON

SOLENOID ON

MAIN BOARD ASSY 19X1931

+18V

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

34 35 36

E13

E18

TO BIAS SUPPLY

F2, 0.9A, (RESETABLE)

PRESS GOOD

INPUT DIODE

ASSY 19X2073

CURRENT

SENSE

-OUT SENSE

TIP SENSE

TIP VOLTS

TORCH SW RTN

TORCH SW

J26 P26

J31 P31

J30

J25 P25

J33 P33

DC COM

+12VDC

CSR

I SENSE

J34 P34

PIP RTN

PIP

J23

28VAC A

GND

28VAC B

J24 P24

E6 E8

E14 E16

1 2

2 3

5 686 7

7 8

1 2

2 3

3 4

4 5

5 66

1 2 3

7 8

E15

E20

E23

E30

1 2

11 2

1 2

E5 E6

E10

E27

E32

TEST CONN

P30

(TS2)

(TS1)

(70) (71) (72) (73) (74) (75)

(77)

ATC CONNECTION CONFIGURATION

(STANDARD)

(78) (79)

(80) (81)

(8)

(9) (10) (11) (12) (13)

MAIN

MAIN TRANSFORMER

PRI

PIP

575 7 4

TORCH

ATC MALE CONNECTOR

ATC RECEIVER

SOL1

GAS SOLENOID

PS1

CONTACTOR

E12A

E17A

24 25

E19A

E21A

IGBT BOARD

ASSY 19X1815

E12B

E17B

24 25

E19B

E21B

IGBT BOARD

ASSY 19X1815

SEC

P39

SOL2

11 15

PRI

SEC

FACTORY INSTALLED OPTIONAL TORCH MOUNTED GAS SOLENOID

PRESSURE SWITCH

CLOSED WHEN PRESSURE OK

WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED, SOL1 IS POWERED BY T6 ONLY ,SOL2 POWERED BY P24-1,-2

GATE

12231314

J3A

J7A

J3B

J7B

2112

P3A

E9A

E11A

P7A

P3B

E9B

E11B

P7B

DRIVE

GATE DRIVE

245

GATE

12231314

DRIVE

GATE DRIVE

24567

74E25E

J39

5 686 7

7 8

APPENDIX A-22 Manual 0-2957

Page 85

COMP DESCRIPTION LOCATION

FUSE, 3/10A 600V FNQ-R

FUSE, 0.9A, RESETABLE

OUTPUT INDUCTOR

M1M2FAN, 4.5" 220VAC

FAN, 4.5" 220VAC

PS1 PRESSURE SWITCH

SOL1 GAS SOLENOID

SWITCH, ON/OFF

SW1

SWITCH, RUN/SET/RAR

SW2

MAIN TRANSFORMER

TS1

TEMP. SENSOR, IGBT HEATSINK

TEMP. SENSOR, INDUCTOR

MAIN CONTACTOR

NOTES: UNLESS OTHERWISE SPECIFIED -

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

C1 F4

4D5T

1E2ST

OUTPUT DIODE ASSEMBLY 19X1757

E34A

E39A

E50A

E48A

E53A E54A

E56A E60A

DC COMMON

POWER OUTPUT BOARD ASSY 19X1914

E58E37

PLUGS INTO J27

ON MAIN BOARD

(LED PCB 19X1604)

ADAPTER HARNESS USED

WHEN REMOTE CURRENT CONTROL IS USED WITH AUTOMATION

(REPLACES CONNECTIONS

FROM J27 TO J14)

OUTPUT INDUCTOR

54E94E

E35

E62

PILOT

E43

JUMPER

OUTPUT DIODE ASSEMBLY 19X1757

E50B

E48B

E53B E54B

E34B

OPTIONAL AUTOMATION INTERFACE CONNECTIONS

J14 P14

TEMP

GAS

E32

E64

E36 E57

E39B

E56B E60B

7 8

E61 E3 E1

CURRENT SENSE

DC COMMON

CSR

(47) (48) (49)

+12VDC

DC COM

ISENSE

J40 P40

CSR

E63

2112 3

(CSR)

(51)

(52)

(TS2)

(TS1)

(NEG)

(NEG)(CSR)

(C1)

(MODE SW)

RAR OFF

(14)

(15)

(17)

(18)

CHASSIS GND THRU SCREW TERMINAL

19X2041

OPTIONAL AUTOMATION INTERFACE

CSR DC COMMON +12VDC

TORCH SW TORCH SW +

(E64)

(E35)

(E62)

(E58)

(52) (51)

(46)

ECO 101136

AA AB AC

ECO 101614 HASAD03/22/05

ECO 101664 HAS 03/24/05

AE AF

ECO B028

ECO B016 RWH 01/27/06

ECO B077

Friday, January 27, 2006

Last Modified:

9 8

E58 E62

1 2

J28

PILOT BOARD ASSY 19X2157

(REL) DLL

ALTERNATE 20-PIN HEADER

DateByRevisionsRev

05/07/03

HASECO 101314

02/11/04

HASECO 101429

06/09/04

01/09/06

07/31/06

RWH

20-POSITION TERMINAL STRIP

TORCH SWITCH

4 5 6

OK TO MOVE 7 8 9

DIVIDED OUTPUT

12 13 14

REMOTE CURRENT CONTROL

15 16

DC COMMON

17 18

C&G

(57)

(59)

(61)

(63)

Information Proprietary to THERMAL DYNAMICS CORPORATION.

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

NOTE:

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)

TITLE:

CM81/101 600V 3PH SYSTEM 42X1134D

CPC

HOUSING

(56)

4 3

(58)

14 12

(60)

6 5

(62)

8 9

(64)

ATC RECEIVER ATC MALE CONNECTOR

T O R C H

WORK

SCHEMATIC,

(+)

TORCH SWITCH

}

(-)

}

OK TO MOVE

(+)

SC-11

}

(-)

LOGIC COMMON

(+)

ARC VOLTS (C&G)

}

(-)

THERMAL DYNAMICS INDUSTRIAL PARK No. 2 WEST LEBANON, NH 03784 603-298-5711

Chk: App:

Art # A-07151

PCB No:

Assy No:

SupersedesScale

Date:

05/07/03

Drawn: References

D.Lilja

Sheet

Sheet 11

DWG No:

Size

Manual 0-2957 A-23 APPENDIX

Page 86

APPENDIX 17: Publication History

Cover Date Rev. Comments

5/5/04 - - Manual Released.

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

6/23/05 - Updated 400V systems to include 415V for Australian per ECO101726

4/28/06 AA Updated per ECO B016 (updated schematics, added c/n for logic board for

mechanized units) and per ECO 101948 (torque spec for replacement input diode). Started using new cover styles. Added publication history.

9/29/06 AA.01 Added patent information and newer rev control. Added inside cover information.

3/14/07 AB.01 Updated 600 volt schematic to show new fuse.

4/13/07 AC.01 Revised C & Cr, revised Troubleshooting section (pg. 4-12) C. 4, 5, 6, made

text corrections, revised Section 6, Parts List, 6.07, Item # 2 - Catalog # 9-8337, updated Inside & Rear Cover.

APPENDIX A-24 Manual 0-2957

Page 87

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermalarc.com

Thermadyne Canada

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-1111 Fax: 905-827-3648

Thermadyne Europe

Europe Building Chorley North Industrial Park Chorley, Lancashire England, PR6 7Bx Telephone: 44-1257-261755 Fax: 44-1257-224800

Thermadyne 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: 61-3-9474-7400 Fax: 61-3-9474-7510

Thermadyne Italy

OCIM, S.r.L. Via Benaco, 3 20098 S. Giuliano Milan, Italy Tel: (39) 02-98 80320 Fax: (39) 02-98 281773

Thermadyne, China

RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 86-21-69171139

Thermadyne International

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-9777 Fax: 905-827-9797

Page 88

Corporate Headquarters

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

Telephone: 636-728-3000 Email: TDCSales@Thermadyne.com

www.thermadyne.com

Thermal Dynamics 81 CUTMASTER Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual