Thermal Dynamics CutMaster 50 Service Manual

Plasma Cutting

Power Supply

CutMaster™ 50

April 21, 2003 Manual No. 0-2806

A-02766

Service Manual

WARNINGS

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™ 50
Service Manual Number 0-2806

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

www.thermal-dynamics.com

Copyright 2000 by
Thermal Dynamics Corporation

All rights reserved.

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

The publisher does not assume and hereby disclaims any liability to
any party for any loss or damage caused by any error or omission in
this Manual, whether such error results from negligence, accident, or
any other cause.

Printed in the United States of America

Publication Date: April 21, 2003

Record the following information for W arranty purposes:

Where Purchased:_______________________________

Purchase Date:__________________________________

Power Supply Serial #:___________________________

Torch Serial #:___________________________________

TABLE OF CONTENTS

SECTION 1:

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

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

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

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

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

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

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

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

1.08 Statement of W arranty.................................................................................. 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 General Description..................................................................................... 3-1

3.03 Specifications/Design Features ................................................................... 3-1

3.04 P ow er Supply Options and Accessories....................................................... 3-2

SECTION 4:

SERVICE TR OUBLESHOOTING DIAGNOSTICS ............................................................ 4-1

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

4.02 P eriodic Inspection & Cleaning Procedures.................................................. 4-1

4.03 System Theory ............................................................................................. 4-1

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

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

4.06 Circuit Fault Isolation .................................................................................... 4-3

4.07 Main Input and Internal Po wer Prob lems...................................................... 4-4

4.08 Pilot Arc Problems........................................................................................ 4-6

4.09 Main Arc Problems....................................................................................... 4-8

4.10 Test Procedures ........................................................................................... 4-8

SECTION 5:

REPAIRS & REPLACEMENT PROCEDURES.................................................................. 5-1

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

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

5.03 Parts Replacement - General Inf ormation .................................................... 5-1

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

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

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

5.07 Rear Panel P arts Replacement .................................................................... 5-7

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

TABLE OF CONTENTS (continued)

SECTION 6:

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

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

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

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

6.04 Front P anel Replacement P arts................................................................... 6-3

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

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

6.07 Rear Panel Replacement P arts ................................................................... 6-8

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

APPENDIX 1: INPUT WIRING REQ UIREMENTS ....................................................................A-1

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

APPENDIX 3-A: LOGIC PC BOARD LAYOUT (For Rev AA Logic Boards)............................... A-3

APPENDIX 3-B: LOGIC PC BOARD LAYOUT (For Rev AB Boards or Later) ...........................A-4

APPENDIX 4-A: MAIN PO WER PC BO ARD LAY OUT (for 208/230-Volt units

with Boards to Rev. G).......................................................................................................A-6

APPENDIX 4-B: MAIN PO WER PC BO ARD LAY OUT (for 208/230-Volt units

with Boards Rev. H and I).................................................................................................. A-8

APPENDIX 4-C: MAIN PO WER PC BO ARD LAY OUT (f or 208/230-Volt units

with Boards Rev. J) .........................................................................................................A-10

APPENDIX 4-D: MAIN PO WER PC BO ARD LAYOUT (for 400-V olt and 460-Volt units ) ........A-12

APPENDIX 5-A: CD PC BOARD LAYOUT (for 208/230-Volt units through Unit Rev AL)........ A-14

APPENDIX 5-B: CD PC BO ARD LAYOUT (for 400-Volt and 460-Volt units,

and 208/230-V olt units Re v AM and later).......................................................................A-15

APPENDIX 6: LED/POT PC BOARD LA YOUT........................................................................A-16

APPENDIX 7: IGBT CIRCUIT PC BO ARD LAYOUT ............................................................... A-17

APPENDIX 8-A: INPUT DIODE PC BO ARD LAYOUT for 208/230-Volt units..........................A-18

APPENDIX 8-B: INPUT DIODE PC BO ARD LAYOUT for 400-Volt and 460-Volt units ............A-19

APPENDIX 9: OUTPUT DIODE PC BO ARD LAYOUT............................................................A-20

TABLE OF CONTENTS (continued)

APPENDIX 10-A: MAIN PC BO ARD WIRING (208/230-Volt units

with Boards Rev. G or earlier) .........................................................................................A-21

APPENDIX 10-B: MAIN PC BOARD WIRING (208/230-Volt units with Boards Re v. H and I) .A-22

APPENDIX 10-C: MAIN PC BO ARD WIRING (208/230-Volt units with Boards Rev. J)........... A-23

APPENDIX 10-D: MAIN PC BO ARD WIRING (for 400-Volt and 460-Volt units) ......................A-24

APPENDIX 11: 28VAC CIRCUIT DIAGRAM........................................................................... A-25

APPENDIX 12: MAINTENANCE SCHEDULE ....................................................................... A-26

APPENDIX 13-A: SYSTEM SCHEMATIC (208/230-V olt units with

Main PC Boards Rev. G or earlier) ..................................................................................A-28

APPENDIX 13-B: SYSTEM SCHEMATIC (208/230-V olt units with

Main PC Board Rev. H or I) ............................................................................................. A-30

APPENDIX 13-C: SYSTEM SCHEMATIC (208/230-Volt units with

Main PC Board Rev. J or later)........................................................................................A-32

APPENDIX 13-D: SYSTEM SCHEMATIC (400-V olt and 460-Volt units) .................................A-34

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 backgr ound 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
HEAL TH.

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 pr ocesses. Y ou 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.”

Date: No v ember 15, 2001 1-1 GENERAL INFORMATION

• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is
moist or damp.

• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publica­tions.

• Disconnect power source before performing any
service or repairs.

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

FIRE AND EXPLOSION

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

• Be sure there is no combustible or flammable ma­terial in the workplace. Any material that cannot
be removed must be protected.

• Ventilate all flammable or explosive vapors from
the workplace.

• Do not cut or weld on containers that may have
held combustibles.

• Provide a fire watch when working in an area where
fire hazards may exist.

• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut under­water or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dis­sipated. T rapped 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.

• T o protect your hearing from loud noise, wear pr o­tective 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 RA YS

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 pr otected.

• 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 HEAL TH 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 OCCU­P ATION AND EDUCA TIONAL EYE AND F ACE 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 Date: Nov ember 15, 2001

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 Standar d 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. NFP A 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 W1 17.2, 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 W elding Society Standard A WSF4.1, RECOM­MENDED SAFE PRACTICES FOR THE PREPARA­TION FOR WELDING AND CUTTING OF CONT AIN­ERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable fr om 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 procédur e 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 RESPIRA TOR Y
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.

Date: No v ember 15, 2001 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 votr e distributeur
local si vous avez des questions.

FUMÉE et GAZ

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

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

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

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

• Réparez ou remplacez toute pièce usée ou
endommagée.

• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différ ents
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. (V oir 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’éner gie
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 Date: Nov ember 15, 2001

RAYONS D’ARC DE PLASMA

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

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

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

• 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 TRA VAIL 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 TRA­V AIL ET DANS LES ECOLES, disponible de l’Institut
Américain des Normes Nationales (American Na­tional Standards Institute), 1430 Broadway, New Y ork,
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. V ous dú4ez vous pr otéger 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 Y ork,
NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS A YANT 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, Batterymar ch Park,
Quincy, MA 02269

Date: No v ember 15, 2001 1-5 GENERAL INFORMATION

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

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

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

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

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

14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRÉPARA TION 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, PRA TIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018

GENERAL INFORMATION 1-6 Date: Nov ember 15, 2001

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street

W est 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.

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 requir ements. 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 boar ds used.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-

ated accessories.

* 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: Giorgio Bassi

Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy

Date: No v ember 15, 2001 1-7 GENERAL INFORMATION

1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in
workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal
products as stated below , Thermal shall, upon notification thereof and substantiation that the product has been stor ed, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair , neglect, alteration, or accident, corr ect such defects by suitable r epair or replacement, at Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PAR TICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal 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 customers of distributor (hereinafter “Purchaser”) for
service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal 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 any goods covered by or furnished by Thermal 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 such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PAR TS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar
and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from
date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).

Parts

XL Plus & Parts Parts

PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Y ears 1 Year 2 Years 1 Year
Original Main Power Rectifier 3 Y ears 1 Year 2 Years 1 Year
Control PC Board 3 Y ears 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Year 1 Y ear 1 Year

But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Y ear 1 Y ear 1 Year
Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Y ear 1 Year
SureLok T orches 1 Y ear 1 Y ear 1 Year
All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair
facility within thirty (30) days of the repair . No transportation costs of any kind will be paid under this warranty. Transportation char ges
to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the
customer ’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective November 15, 2001

GENERAL INFORMATION 1-8 Date: Nov ember 15, 2001

SECTION 2:

2.03 Service Responsibilities

INTRODUCTION

2.01 Scope Of Manual

This manual provides service instructions for the Ther­mal Dynamics CutMaster 50 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 (0-2805).

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

2.02 General Service Philosophy

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

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

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

A. Application

The equipment should satisfy the customer ’s require­ments as supplied and as described in Section 3 of this
manual. Be sure to confirm that the equipment is capable
of the application desired.

B. Modifications

No physical or electrical modifications other than selec­tion of standard options and Accessories are to be made
to this equipment.

C. Customer/Operator Responsibilities

It is the customer/operator's responsibility to maintain
the equipment and peripheral accessories provided by
Thermal Dynamics in good operating order in accordance
with the procedures outlined in the operating manual,
and to protect the equipment from accidental or mali­cious damage.

D. Repair Restrictions

The electronics consists of Printed Circuit Board (PCB)
Assemblies which must be carefully handled and must
be replaced as units. No replacement of printed circuit
solder-mounted components is allowed except as noted
in this manual.

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

Manual 0-2806 2-1 INTRODUCTION

INTRODUCTION 2-2 Manual 0-2806

SECTION 3:

p

p

2. Front Panel LED Indicators

DESCRIPTION

3.01 Scope

The purpose of this section is:

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

• T o pr ovide an overall understanding which will al­low the technician, in turn, to properly train cus­tomer operating personnel.

3.02 General Description

The power supply provides 40 amp maximum output and
includes all control circuitry, electrical and gas inputs and
outputs, pilot circuitry, torch & leads, work cable with
clamp, and input power cable (and plug, on 208/230V
units).

• AC TEMP

• GAS DC

3. Rear Panel Features

• Primary Input Power Cable (with Molded Plug, on
208/230V units only)

• Gas Pressure Regulator/Filter Assembly

• Gas Supply Connection

4. Input Power (See Note)

• 208/230 VAC, (±10%) Single-Phase

• 400VAC, (±10%) Three-Phase

• 460VAC, (±10%) Three-Phase

• 460VAC, (±10%) Single-Phase

NOTE

Refer to Appendix 1 for input wiring requirements.

5. Output Power

Continuously variable from 20 to 40 amps maximum

A-02766

CutMasterTM 50 Power Supply

3.03 Specifications/Design Features

A. Power Supply Technical Specifications

The following specifications apply to the Power Supply
only:

1. Front Panel Features

• Main Power ON/OFF Switch

• RUN/SET Switch

• Torch Leads Access

• Work Cable

• Output Current Control

6. Duty Cycle (see NOTE)

NOTE

The duty cycle will be reduced if the primary in­put voltage (AC) is low or the DC voltage is higher
than shown in the chart.

208/230-Volt Power Supply Duty Cycle:

208/230 Vol t Power Supply Duty Cycle

Ambient

erature

Tem

Duty Cy cle

Current

DC Vol ta g e

400-Volt and 460-Volt Power Supply Duty Cycle:

400-Volt, 460-Volt Power Supply Duty Cycle

Ambient

erature

Tem

Duty Cy cle

Current

DC Vol ta g e

104° F

(40° C)

40% 60% 100%

39 Amps 33 Amps 20 Amps

110 vdc 105 vdc 100 vdc

104° F

(40° C)

40% 60% 100%

40 Amps 33 Amps n/ a

110 vdc 105 vdc n/ a

104° F

(40° C)

104° F

(40° C)

104° F

(40° C)

104° F

(40° C)

Manual 0-2806 3-1 DESCRIPTION

7. Pilot Circuitry

Capacitive Discharge (CD), Ignition DC Pilot

8. Weight

Power Supply w/Input Cable & W ork Lead, T orch &
Leads - 52 lbs. (23.6 kg).

9. Overall Dimensions (w/handles)

Length 22-1/2" (571 mm)

D. Hand Pendant Control (for machine

applications only)

A hand pendant contr ol with 25 ft (7.6 m) cable which
provides ON/OFF signals to the power supply.

E. Hand Pendant Control Extension

Also offered is a 25 ft (7.6 m) extension cable which
when added to the Hand Pendant Control, provides

a total cable length of 50 ft (15.2 m).
Width 10-3/4" (273 mm)
Height 16-3/8" (416 mm)

B. Gas Regulator/Filter Assembly

Specifications

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

1. Operating Pressure

65 psi (4.5 bar)

2. Maximum input gas supply pressure

125 psi (8.6 bar)

3. Filter

Particulate Type Filter (to 20 microns)

3.04 Power Supply Options and
Accessories

The following accessories are available for this power
supply. Refer to Section 6, Parts Lists, for catalog num­bers and ordering information.

F. Wheel Kit

A kit with easy-rolling wheels, for maximum port­ability.

G. Multi-Purpose Cart

Rugged steel cart on easy-rolling rear wheels and front­mounted swivel casters. Provides maximum mobility
for the power supply and can also serve as a display
cart. Top shelf is 12" (305 mm) x 20 (508 mm). Steel
handle is 30" (762 mm) high.

A. Single Stage Air Line Filter Kit

A Single Stage In-Line Air Filter for use with com­pressed air shop systems. Filters moisture and par­ticulate matter from the air stream to at least 0.85 mi­crons.

B. Two Stage Air Line Filter

A Two Stage In-Line Air Filter for use on compressed
air shop systems. Filters moisture and particulate
matter from the air stream to at least 5.0 microns.

C. Extended Work Cable with Clamp

As an alternative to the standard 20 ft (6.1 m) work
cable & clamp factory installed on the power supply ,
an optional 50 ft (15.2 m) work cable with clamp is
available.

DESCRIPTION 3-2 Manual 0-2806

SECTION 4:

SERVICE

TROUBLESHOOTING

DIAGNOSTICS

4.01 Introduction

A. Logic PC Board Functions

The Logic PC Board controls the timing and sequenc­ing of the system. It monitors gas pressure and inter­nal temperature, and controls the gas flow in Run and
Set modes.

After the ON/OFF switch on the front panel is closed,
the AC Indicator blinks for approximately eight sec­onds, then becomes steady and the Main Contactor
closes.

This section provides diagnostics for the CutMaster 50
Power Supply, allowing the Technician to isolate any
faulty subassemblies. Refer to Section 5, Repairs & Re­placement Procedures, for parts replacement instr uctions.

The CutMaster 50 Power Supply is available for several
input voltages. This Service Manual covers all types.
Special attention is required to ensure that the technician
selects the proper test points and measurements for the
Power Supply being serviced.

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

This manual covers the Power Supply only.
Troubleshooting other parts of the system is cov­ered in separate manuals for those products.

4.02 Periodic Inspection & Cleaning
Procedures

This subsection describes inspection procedures which
should be performed at periodic intervals as required.

A. Physical Inspection

Check that all wiring connections are secure.

B. Cleaning

Open the enclosure per 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 Appendix 12 for maintenance schedule and
procedures. Clean or replace filters per Section 5.07.

4.03 System Theory

When the unit is at 'idle' the AC Indicator on the Front
Panel should be ON. When the torch is activated, the
gas starts to flow . When the pr eflow time is over, the
INV ON signal is given and the DC indicator on the
Front Panel turns ON.

When the torch is activated (press torch switch, send
ST ART signal fr om CNC Controller or press the tor ch
switch on the Remote Pendant), gas flows for approxi­mately two seconds before DC is established (indi­cated on the front panel). During this time CD En­able indicator on the Logic Board comes on and sends
a signal to the CD Board which fires the spark gap
and starts the pilot arc. The indicator should go out
immediately if the pilot starts immediately.

CutMaster 50 Logic P CB Indic at ors

INV O N CD E na ble

Rev. A A Logic PCB D7 D19

Rev AB+ Logic PCB D13 D16

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. If the torch is removed from
the workpiece while the torch is still activated, the
main arc extinguishes and the pilot arc automatically
restarts.

A circuit on the Logic Boar d monitors the output volt­age. When the output voltage drops below 60 vdc,
indicating a problem exists, the Logic Board turns off
the INV ON enable signal.

B. CD (Capacitive Discharge) Board Functions

A signal from the Logic PC Board initiates the CD
Board functions. The CD arc starting circuit pr oduces
the high voltage spark which starts the DC pilot arc.
When the Logic Board senses a pilot arc, the signal
shuts off the CD enable indicator.

The CutMaster 50 System is designed for hand cutting
and mechanized operation using the torch control bulk­head within the power supply as the interface.

Manual 0-2806 4-1 SERVICE TROUBLESHOO TING

4.04 Common Operating Problems

WARNINGS

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

Frequently review the Important Safety Precau­tions in Section 1 of this manual. 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 scraped off
easily . 'High speed dross' usually forms a narr ow bead
along the bottom of the cut edge and is very difficult
to remove. When cutting a troublesome steel, it is
sometimes useful to reduce the cutting speed to pro­duce 'slow speed dross'. Any resultant cleanup can
be accomplished by scraping, not grinding.

F. Common Cutting Faults

Handle torch leads with care and protect them fr om
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.

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

3. Excessive Dross Formation

a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Worn torch parts
d. Improper cutting current
e. Non-Genuine Thermal Dynamics parts used

4. Short Torch Parts Life

a. Moisture in air source

SERVICE TR OUBLESHOOTING 4-2 Manual 0-2806

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

1. Perform operational check(s) on the equipment to iso­late problem to possible circuit(s) per Subsection 4.06,
Circuit Fault Isolation.

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)

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

The CutMaster 50 Operating Manual describes basic
troubleshooting and parts replacement procedur es.

This Service Manual covers advanced troubleshooting,
which requires power supply disassembly and live mea­surements. Advanced tr oubleshooting and repair of this
unit 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.

The troubleshooting guide has subsections as follows:

Section 4.06 - Circuit Fault Isolation
Section 4.07 - Main Input and Internal Power Prob-

lems
Section 4.08 - Pilot Arc Problems
Section 4.09 - Main Arc Problems
Section 4.10 - Test Procedures

Subsection 4.10 includes specific test procedures, indica­tions, and measurements. The subsection is referenced
by the troubleshooting guide for the specific test to be
performed.

B. How to Use the Troubleshooting Guide

a. Check/Remedy (T ext 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. Remedies
may have different specific information depending on
the input voltage of the power supply.

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.

4.06 Circuit Fault Isolation

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.

A. Initial Setup Conditions

1. Connect gas supply to rear of Power Supply .

2. Turn on gas supply and adjust Power Supply Gas
Regulator to 65 psi (4.5 bar).

3. Set the Power Supply controls as follows:

• ON/OFF switch to OFF

• RUN/SET switch to SET

• CURRENT (AMPS) control knob to maximum

The following information is a guide to help the Service
Technician determine the most likely causes for various
symptoms. This guide is set up as follows:

Manual 0-2806 4-3 SERVICE TROUBLESHOO TING

B. Main Input and Internal Power Tests

1. Connect main AC power to the unit.

2. Set the Power Supply ON/OFF switch to ON and note
the following:

• AC indicator blinks for eight seconds (ap­proximately), then steady ON

• Relay K4 on Main PC Board energizes (clicks) while
AC indicator is blinking

• Relay K2 energizes, pulling in Main Input Contactor
W1 after AC light stops blinking.

• TEMP Indicator OFF

• GAS Indicator ON

• Gas flows

• Fan will operate

• DC lndicator is OFF

3. Set the Power Supply RUN/SET switch to the RUN
position and note the following:

This completes the Main Arc Test. If the equipment op­erates as described, proceed to Subsection 4.07. If prob­lems still persist then contact Technical Services.

If the equipment does not function as described, note the
symptom and proceed to Subsection 4.09, Main Ar c Prob­lems.

4.07 Main Input and Internal Power
Problems

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. Refer to Subsection 5.07-D, Input Power Cable

Replacement procedures, and check that the in­put power cable is not defective or installed
incorrectly.

B. Main power line fuses blow immediately after the

ON/OFF Switch is turned on.

• Gas indicator goes OFF

• Gas flow stops

This completes the Main Input and Internal Power T ests.
If the unit functions as described then proceed to para­graph 'C'. If the unit does not function as described then
note the symptom and proceed to Subsection 4.07, Main
Input and Internal Power Problems.

C. Pilot Arc Test

1. Establish a pilot arc and note the following:

• Gas flows

• GAS indicator turns ON

• Preflow delay (two seconds) then DC indicator turns
ON

• Pilot arc established

This completes the Pilot Arc Test. If the equipment oper­ates as described then proceed to paragraph 'D'. If the
equipment does not function as noted then note the symp­tom and proceed to Subsection 4.08, Pilot Ar c Pr oblems.

D. Main Arc Test

Activate the Torch to establish a pilot arc.
Bring the torch to within 1/8"-3/8" (3-10 mm) of the work-

piece to establish the main cutting arc, and note the fol­lowing:

• Main cutting arc starts

• Pilot Relay PCR opens

1. Faulty Input Diode
a. Test Input Diode per Subsection 4.10-D; r epair

as necessary.

C. Fan does not operate; AC indicator on front panel

of power supply is OFF

1. Front Panel ON/OFF switch in OFF position

a. Place switch to ON position.

2. Main power disconnect not closed

a. Close main power disconnect.

3. Main power line fuses blown

a. Replace main power line fuses.

4. Improper input power cable connections inside Power

Supply

a. Refer to Subsection 5.07-D and correct if

needed.

5. Defective input power cable

a. Replace input power cable.

6. Fuse blown inside Power Supply

a. Replace internal Fuse per Subsection 5.06-A.

7. Line voltage above 10% tolerance (over voltage pro-

tection)

a. Reduce line supply .

SERVICE TR OUBLESHOOTING 4-4 Manual 0-2806

8. Faulty ON/OFF switch (refer to Appendix 11, 28 VAC
Circuit Diagram).

D. System will not pilot; AC indicator ON, TEMP

indicator ON

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

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

Switch.

J3-6

Logic
PC Board
Connector

J3-5

A-02923

9. Faulty Auxiliary Transformer (refer to Appendix 11,
28 VAC Circuit Diagram)

1. Air flow through unit is restricted

a. Provide adequate air flow. Refer to Operating

Manual for air flow requirements.

2. Exceeding Duty Cycle of Power Supply

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

Refer to Section 3 for Duty Cycle specifications.

3. Faulty Fan

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

• If voltage is correct, replace Fan Assembly.

Auxiliary
Transformer

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

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

PC Board.

J5

Auxiliary
Transformer

A-02924

J2 J23

Logic PCB

10. Faulty Main Power PC Board (refer to Appendix 4-A,
4-B, 4-C, or 4-D, Main Power PC Board Layout)

Measure for 12 VAC from TP5 to TP1 on main
power PC board.

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

Board.

A-02925

J26-4

J26-1

E. No gas flow; AC indicator ON; TEMP indicator

OFF; GAS and DC indicators OFF

1. RUN/SET switch in RUN position

a. Switch to SET position.

2. Gas supply not connected to unit

a. Connect to gas supply.

3. Gas supply not turned on

a. Turn gas supply on.

4. Faulty RUN/SET switch
a. Check continuity.

5. Faulty Gas Solenoid circuit

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

repair as necessary.

F. Gas flows; AC indicator ON; GAS indicator OFF;

DC indicator OFF

1. Gas pressure too low

a. Refer to torch manual for operating pressures.

Manual 0-2806 4-5 SERVICE TROUBLESHOO TING

2. Faulty Pressure Switch

Measure for 12 vdc from wire #9 to wir e #10 at the
Gas Pressure Switch, located on the right side of
the unit.

a. If voltage is present and pressur e is above 50

psi (3.4 bar), replace Gas Pressure Switch/
Solenoid Assembly.

b. If voltage is not present, replace the Logic PC

Board.

3. Faulty Wiring or Faulty Logic PC Board

Check DC voltage at Main Power PCB pin J4-3 to
J4-4 from the Logic PC Board.

• If less than a volt, replace Logic PC Board.

J4-4

A-02926

J4-3

G. Arc in torch without activating torch; AC indicator

ON; Gas flows; GAS and DC indicators ON

1. Faulty torch switch

a. Refer to appropriate T orch Instr uction Manual

and check continuity.

2. Faulty torch leads

a. Refer to appropriate T orch Instr uction Manual

and check continuity.

J9-3

J9-1

A-02927

4.08 Pilot Arc Problems

Locate your symptom below:

A. No gas flow; AC indicator ON; TEMP indicator

off; GAS and DC indicators OFF (Torch must be
activated)

1. Faulty torch switch
a. Refer to Torch Instruction Manual and check

torch switch continuity.

2. Faulty RUN/SET Switch

a. Check switch and replace as necessary.

3. Faulty Logic PCB

a. Measure the voltage between J1-22 to J1-20.

Voltage should be less than 2 vdc.

• If less than 2 vdc, replace logic PCB. If greater

than 2 vdc, replace Main PCB.

b. Check for damaged torch leads. If pilot wire

arcs to torch switch PIP lead it can cause dam­age to either PCB as well as the torch leads.

3. Faulty Main Power PC Board

a. Disconnect J9 Connector from the Main PC

Board. Refer to Appendix 4-A, 4-B, 4-C, or

4-D.
b. Unplug Logic PC Board.
c. Measure across pins J9-1 and J9-3 on Main

Power PC Board. If less than 2K ohms, replace

Main Power Board. If more than 2K ohms, re-

place Logic PC Board.
d. Check for damaged torch leads. If pilot wire

arcs to torch switch PIP lead it can cause dam-

age to either PCB as well as the torch leads.

SERVICE TR OUBLESHOOTING 4-6 Manual 0-2806

B. Gas flows; Small arc may be visible in torch; AC

indicator ON; TEMP indicator OFF; GAS indica­tor ON; DC indicator blinks

1. Faulty Main Power PC Board or Shorted T orch

a. Test per Subsection 4.10-G; repair as necessary.

2. Faulty IGBT or Output Diode Module Assembly

a. Check per Subsection 4.10-G; repair as neces-

sary.

3. Faulty torch

a. Check torch per appropriate Torch Instruction

Manual.

C. No arc in torch; No arc at spark gap on CD PC

Board; AC indicator ON; TEMP indicator off; Gas
flows; GAS and DC indicators ON; CD enable
indicator ON

1. Faulty CD PC Board

NOTE

Check the size of the CD PCB.

Power Supplies with 4" x 7" (102 x 178mm) CD
Board:

Measure for OCV (dc) at J11-4 to J11-5 when

the torch is activated.

• If less than 2 vdc check pins J11-1 to J11-3
for approximately 28 VAC.

• If voltage is present, replace CD Board.

If there is no voltage, replace Main T rans­former (T5).

• If there is no 28 V AC, r eplace Main T rans-

former per Section 5.08-D.

J11-1
J11-3

J11-4

J11-5

J28-1

J28-2

J28-5

J28-8

A-03087

D. No arc or intermittent arc in torch; Gas flows; AC

indicator ON; TEMP indicator OFF; GAS and DC
indicators ON; Spark at gap on CD PC Board; CD
enable indicator on Logic PC Board ON

1. Gas pressure set incorrectly (too high)

a. Refer to appropriate To rch Manual.

2. Oil/moisture in air lines

a. Purge system. If problem is corrected, add fil-

ters in line with air source.

A-02928

Power Supplies with 3-1/2" x 4" (89 x 102 mm)
CD Board:

If available, check with an oscilloscope from
J28-5 to J28-8 for approximately 500 V AC peak­to-peak (18 khz switching frequency).

• If there is no 500 V AC, r eplace main power
transformer (T5).

• Check for +12vdc between J28-1 on CD PC
Board and TP-1 on Main Power PC Board.

• Measure for less than 2vdc between J28-2
on CD PC Board and TP-1 on Main Power
PC Board.

• If voltages are present, replace CD PC
Board.

3. Incorrect torch parts

a. Refer to appropriate Tor ch Instruction Manual.

4. Faulty leads

a. Check continuity per appropriate T or ch Instruc-

tion Manual.

5. Faulty torch

a. Check continuity per appropriate T or ch Instruc-

tion Manual.

6. Faulty connection of wire #33 to Main Power PC Board

a. Check wiring connection.

7. Faulty Main Power PC Board

• Units with Rev AA Logic Board: Check for
approximately 12 vdc at TP4 to TP1 on the Logic
PC Board. If less than 2 vdc, replace the Main
Power Board.

• Units with Rev AB or later Logic Board: Check
for approximately 12 vdc at TP2 to TP1 on the
Logic PC Board. If less than 2 vdc, replace the
Main Power Board.

Manual 0-2806 4-7 SERVICE TROUBLESHOO TING

8. Faulty PCR Relay

Install a jumper between wires on PCR Relay as
indicated below. Try piloting again.

• 208/230V Power Supplies with Main PC Board

through Rev G: Jumper wires # 33 and 32.

For 208/230V units with Rev H or later Main PC

Boards, and all 400V and 460V units:
Arc shuts off during operation; Arc will not re-

start when torch switch is activated.

1. Unit is overheated (TEMP indicator ON)

• All other Power Supplies: Jumper wires #33

and 43.

a. If torch pilots with jumper installed, replace

PCR Relay.

4.09 Main Arc Problems

Locate your symptom below:

A. Main cutting arc will not initiate

1. Work cable not connected.

a. Connect work cable.

2. Holding too high of a standoff

a. Refer to Operating Manual for recommended

standoff heights.

3. Workpiece is painted or rusty.

a. Clean workpiece.

4. Faulty Main Power PC Board or Logic Board.

a. Units with Rev AA Logic Board: Measure for

0 vdc at TP4 to TP1 on the Logic Board when
attempting to transfer .

a. Let unit cool down for at least five minutes.

Make sure unit has not been operated beyond
Duty Cycle limit. Refer to Section 3 for Duty
Cycle specifications.

2. Fan blades blocked (TEMP indicator ON)

a. Check and clear blades.

3. Air flow obstructed (TEMP indicator ON)

a. Check for obstructed air flow around the unit

and correct condition.

4. Gas pressure too low (GAS indicator OFF when torch
is activated).

a. Check source for at least 65 psi (4.5 bar); adjust

as needed.

5. Faulty components in unit.

a. Return for repair or have qualified technician

repair per Service Manual.

4.10 Test Procedures

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

Units with Rev AB or later Logic Board: Mea­sure for 0 vdc at TP2 to TP1 on the Logic Board
when attempting to transfer.

• If TP4 (or TP2) goes to 0 volts replace Logic
Board. If not, replace Main Power PC Boar d.

5. Faulty Main Input Contactor.

a. Check per Subsection 4.10E.

B. When operating the amperage drops off after the

main cutting arc transfers.

1. Faulty Pilot (PCR) Relay

• 208/230V Power Supplies with Main PC Board
through Rev G: With power off, test for conti­nuity between wires #32 and #33. If continuity
is found, replace PCR.

• 208/230V Power Supplies with Main PC Board

Rev H or later, and all other Power Supplies:

With power off, test for continuity between
wires #33 and #43. If continuity is found, re­place PCR.

A. Safety Precautions

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

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

3. Keep away from any moving parts.

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

5. Electrostatic discharge can damage printed circuit
board assemblies. T ransport printed cir cuit 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.

SERVICE TR OUBLESHOOTING 4-8 Manual 0-2806

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

B. Opening Power Supply Enclosure

C. Diode Testing Basics

T esting of diode modules r equires 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.

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

WARNING

Disconnect primary power at the source before as­sembling or disassembling the Power Supply, torch
parts, or torch and leads assemblies.

1. Remove the upper screws securing the cover to the
main assembly.

2. Loosen, but do not remove, the lower screws.

NOTE

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

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

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

1. Locate the diode module to be tested.

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

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

4. Using the Figures for each test, check each diode in
the module. Each diode must be checked in forward
bias (plus to negative) and reverse bias (negative to
plus) direction.

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

A-00307

0.75

Forward Bias

Diode Conducting

Lower screws

Upper screws

Ground wire

A-02776

Diode T est Symbol

Anode

Cathode

VR

+

COM

_

A

Testing Diode Forward Bias

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

Manual 0-2806 4-9 SERVICE TROUBLESHOO TING

Reverse Bias

Diode Not Conducting

OL

A-00306

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

Met e r (+) M eter (-) Indication

All

Voltages

400/460V

Only

L1 T1 Open
L2 T2 Open

L2 T1 Open

Cathode

Anode

VR

+

COM

_

A

Testing Diode Reverse Bias

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

8. Reconnect all cables to proper terminals.

D. Input Diode Test

Check Input Diode for shorted input diode.
Remove AC power and with an ohmmeter set on the di-

ode range make the following checks on Main PC Board:

For 208/230V Power Supplies:

Mete r (+) Meter (-) Indica tion

E2 E11 Diode Drop
E11 E2 Open
E12 E2 Diode Drop

E2 E12 Open

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

E. Main Input Contactor (W1) Test

Reconnect power and observe proper start-up procedure.
AC LED 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 LED Indicator on Front Panel is OFF, check
for proper input AC voltage at the Main Contac­tor. If voltage is not correct (refer to following
chart), check for proper AC voltage at the main
power source.

CutMaster 50 Input Contac t or V ol t age Ranges

Input

Power

Test Points

208/230V L1, L2 187-253VAC

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

208/230V Power Supply Input Contactor:

Input
Cable (L1)

Wire #12

Voltage

Range

For 400V and 460V Power Supplies:

Mete r (+) Meter (-) Indica tion

E1 E11 Diode Drop

E11 E1 Open

E2 E11 Diode Drop

E11 E2 Open

E3 E11 Diode Drop
E11 E3 Open
E12 E1 Diode Drop

E1 E12 Open
E12 E2 Diode Drop

E2 E12 Open
E12 E3 Diode Drop

E3 E12 Open

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

SERVICE TR OUBLESHOOTING 4-10 Manual 0-2806

Input
Cable (L2)

Wire #11

Label

A-03223

400V and 460V Power Supply Input Contactor:

To E2

To E3

Connections to

Main PCB

To E1

T1 T2 T3

L1 L2 L3

Input Side

L3

L2

L1

#12

#11

Main Contactor

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

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

F. Gas Solenoid Circuit Test

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

Label

A-03224

CutMaster 50 Logic P CB Indic at ors

INV O N CD E na ble

Rev. A A Logic PCB D7 D19

Rev AB+ Logic PCB D13 D16

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

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

a. Disconnect eight-pin wire harness connector

from the CD PC Board to disable the CD sig­nal.

WARNING

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

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

dicator , turns ON).

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

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

1. Place the RUN/SET Switch to the SET position.

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

• If 28V AC is present, r eplace Solenoid/Pressure
Switch Assembly. If 28VAC is not present, go
to the next step.

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

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

G. IGBT Module Board/Output Diode Module

Board Circuit Test

1. No DC Output

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

2. Output Diode Module Board Circuit Test

WARNING

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

a. Use an ohmmeter set to the diode function and

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

Mete r (+) Meter (-) In d ica tion

E18 E 21 Diode Drop
E21 E18 Open
E18 E 20 Diode Drop
E20 E18 Open
E20 E 19 Diode Drop
E19 E20 Open
E21 E 19 Diode Drop
E19 E21 Open
E18 E 19 (2) Diode Drops
E19 E18 Open

Manual 0-2806 4-11 SERVICE TROUBLESHOO TING

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

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

3. IGBT Module Board Circuit Test

a. Use an ohmmeter set to the diode function and

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

CM50 IGBT Test Indications

208/230V

Power Supply

Meter (+) Meter (-) Meter (+) Meter (-) Indicati on

E3 E13 E35 E13 Diode Drop
E13 E3 E13 E35 Open
E15 E 3 E15 E 35 Diode Drop

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

400V & 460V

Power Supply

c. Activate the torch (press torch switch on the

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

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

• If INV ON LED does remain on, then check for
approximately 6 vdc between J1-29 and J1-28
and between J1-27 and J1-26.

• If no voltage, replace Logic PC Board.

• If voltage is correct, measure for approxi-

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

• If 0 vdc, replace Main PCB.

• If correct, reconnect wires to Main PC
Board.

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 if readings
are not the same as the chart.

c. Activate the torch.

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

CutMaster 50 Logic P CB Indic at ors

INV O N CD E na ble

Rev. A A Logic PCB D7 D19

Rev AB+ Logic PCB D13 D16

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

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

4. Gate Drive & DC Sensing

a. After checking all previous steps in Subsection

4.09-G, jumper TP1 to TP3 on the Logic PCB.

d. With jumper between TP1 to TP3 still in place, ac-

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

• If 0 vdc, replace IGBT PC Board.

• If correct, replace Logic PC Board.

This completes the test procedures.

b. Disconnect wires from the Main PC Board as

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

Main P C Board Wire Disconnection P oi nts

208/230V Uni ts E3, E13, E15

400V, 460V Unit s E13, E 15, E 35

SERVICE TR OUBLESHOOTING 4-12 Manual 0-2806

SECTION 5:

REPAIRS & REPLACEMENT

PROCEDURES

5.01 Introduction

This section describes parts replacement procedur es and
all repairs which may be performed on the CutMaster 50
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. W rap the adhesive side firmly around
your wrist.

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

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

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

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

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

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

A. General

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

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

WARNINGS

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

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

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

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

9. Replace the power supply cover.

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

5.03 Parts Replacement - General
Information

The parts replacement procedures described in this
manual, except for filter replacement, require that the
Power Supply be disassembled. The part to be replaced
will determine to what extent the Power Supply must be
disassembled.

Before removing any connection mark each wire with the
connection designation. When reassembling make sure
the wires go to the proper terminals.

Note the routing of wires and make sure the wires are
put back in the same place when re-assembling the unit.

Each subsection is referenced to Section 6 for parts lists
and overall detailed drawings.

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

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

Manual 0-2806 5-1 REPAIRS & REPLACEMENT PROCEDURES

WARNING

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

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

5.04 Major External Parts
Replacement

B. Tube Handle Replacement

1. Remove the cover per Subsection 5.04-A.

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

WARNING

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

A. Cover Removal and Replacement

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

Upper screws

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

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

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

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

Lower screws

Ground wire

A-02776

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

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

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

A-02847

5.05 Front Panel Parts Replacement

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

WARNING

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

A. CURRENT Knob Replacement

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

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

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

4. Tighten the scr ew to secure the knob to the poten­tiometer shaft.

REPAIRS & REPLACEMENT PROCEDURES 5-2 Manual 0-2806

B. ON/OFF Switch Replacement

D. POT/LED PC Board Replacement

1. Remove the cover per Subsection 5.04-A.

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

Top clip

Wire #21

Wire #24

Wire #22

Wire #23

A-02774

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

4. Install the replacement ON/OFF Switch by revers­ing the above steps.

C. RUN/SET Switch Replacement

1. Remove the cover per Subsection 5.04-A.

2. Disconnect the two wires on the rear of the RUN/
SET Switch, noting the location and orientation of
each wire, as shown below:

Follow the antistatic procedures in Subsection 5.02.

1. Remove the cover per Subsection 5.04-A.

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

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

4. Remove PC Board from standoffs.

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

E. Work Cable Replacement

1. Remove the cover per Subsection 5.04-A.

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

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

4. Remove Work Cable from the unit.

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

5.06 Left Side Internal Parts
Replacement

Refer to Subsection 6.05 Left Side Internal Replacement
Parts.

Top clip

Wire #25

Wire #26

A-02775

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

4. Install the replacement RUN/SET Switch by re­versing the above steps.

WARNING

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

A. Fuse Replacement

1. Remove the cover per Subsection 5.04-A.

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

3. Install replacement fuse.

4. Reinstall the cover .

Manual 0-2806 5-3 REPAIRS & REPLACEMENT PROCEDURES

B. Main Input Contactor Replacement

C. Pilot Relay Assembly (PCR)

1. Remove the cover per Subsection 5.04-A.

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

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

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

5. Connect the wiring as shown below.

NOTE

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

For 208/230-Volt Power Supplies:

White Input
Cable (L1)

Blue
Wire #3

Blue
Wire #4

Blue
Wire #12

Black
Cable #2

T1

T2

1. Remove the cover per Subsection 5.04-A.

2. Carefully remove all wire connections to the Re­lay Assembly, as shown below:

Wire Connections

Jumper
Wire #34

A-02848

Label

Wire #19

Wire #20

3. Remove the two nuts securing the Mounting Plate
to the base or front panel of the unit.

4. Remove Relay from Mounting Plate.

5. Install the replacement Relay Assembly by revers­ing the above steps. The label on the Pilot Relay
must face outwards.

D. Logic PC Board Replacement

Black Input
Cable (L2)

A-02849

Blue
Wire #11

Label

Black
Cable #1

For 400-Volt and 460-Volt Power Supplies:

To E2

To E3

Connections to

Main PCB

To E1

T1 T2 T3

L1 L2 L3

Input Side

L3

L2

L1

#3

#12

#11

#4

Main Contactor

Label

A-03176

Follow the antistatic procedures provided in Subsection

5.02.

1. Remove the cover per Subsection 5.04-A.

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

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

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

a. The pins on the Logic Board must be fully

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

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

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

6. Reinstall cover .

REPAIRS & REPLACEMENT PROCEDURES 5-4 Manual 0-2806

E. IGBT Circuit Board, Input Diode, or Output

Diode Replacement

Follow the antistatic procedures in Subsection 5.02.

For input diodes on 400 or 460-Volt units only:
a. Cut away one side of the round pad, about

1/4” (6 mm) at the widest, to accommodate
the Main PC board standoff on the chassis.

WARNINGS

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

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

1. Remove cover per Subsection 5.04-A.

2. Turn the Power Supply onto its side.

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

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

5. For input diodes:

If there is a solid metal disk attached to the chas­sis, remove it by twisting it and pulling it away
from the chassis. Thoroughly clean both sides of
the metal disk with isopropyl alcohol and a clean
rag. Do not scratch or abrade the surface.

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

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

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

7. For IGBT s, remove the small jumpers from the com­ponent being replaced. Transfer the jumpers to
the replacement component.

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

9. Install modules as follows:

For IGBTs and output diodes:

a. Put the replacement module in position, and

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

For input diodes:

a. Put the solid metal disk on the round thermal

pad applied to the heatsink. Center the disk
on the bolt hole in the chassis.

b. Place the rectangular thermal pad on the solid

disk. Center the pad on the hole in the solid
disk.

c. Pass the longer screw provided in the replace-

ment kit through the flat washer removed pre­viously.

d. Secure the diode, rectangular pad, and solid

disk to the chassis with the replacement screw .
Ensure that the rectangular pad is aligned with
the rectangular flat surface on the back of the
diode.

For all diodes and IGBTs:

a. Torque the scr ew to 17 inch-pounds (1.9 Nm).

CAUTION

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

For output diodes:

a. Cut away one side of the pad, about 1/4”

(6 mm) at the widest, to accommodate the ther­mal switch on the heatsink.

Manual 0-2806 5-5 REPAIRS & REPLACEMENT PROCEDURES

CAUTION

Failure to torque properly will cause component
damage.

Round Thermal P ad
(1 only; See Note B)

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

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

Diode
or IGBT

Solid Disk and

WasherScrew

NOTES
A: Present for input diodes only.
B: Position pad with trimmed edge at bottom
for CutMaster 50, 400-V and 460-V input
diodes only.
Position pad with trimmed edge at right
for CutMaster 50 output diodes only.

Rectangular Thermal
Pad (See Note A)

A-03231

10. Reconnect the wiring per the applicable chart.

Input Diode W iri ng Connections

208/230V

Power Suppli es

From Input

Diode

To Main PCB

400V, 460V

Power Suppli es

From Input

Diode

To Main PCB

E22, E 23 E 2 E26, E27 E12
E26, E 27 E 12 E 24, E25 E 11
E24, E 25 E 11 E44 E1

E23 E2
E22 E3

F. Main PC Board Replacement

Follow the antistatic procedures provided in Subsection

5.02.

1. Remove cover per Subsection 5.04-A.

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

3. Remove the POT/LED PC Board per Subsection

5.05-D.

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

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

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

Auxiliary T ransf ormer

(gnd)

IGBT Wiring Connec t i ons

208/230V

Power Suppli es

Power Suppli es

From IGBT To Main PCB From IGBT to Main PCB

E28, E 29 E 13 E28, E 29 E 13
E30, E 31 E 3 E30, E31 E35
E32, E 33 E 15 E32, E 33 E 15

J18 J20 J18 J20
J19 J21 J19 J21

Output Diode Wiring Connect i ons

From Output

Diode

To Main PCB

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

REPAIRS & REPLACEMENT PROCEDURES 5-6 Manual 0-2806

(gnd)

400V, 460V

A-02781

7. Carefully remove the original PC Board.

8. Install the replacement PC Board by reversing
steps above. It may be easier to install the PC Board
if the Power Supply is turned on its right side first.

9. Refer to the instructions provided with the replace­ment PC Board, or the Appendix pages in this
manual, for wiring details.

E21
E19
E18
E20

5.07 Rear Panel Par ts Replacement

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

WARNING

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

A. Filter/Regulator Assembly Replacement

For Power Supplies with Type B Filter/Regulator:

a. Remove the nut securing the Filter/Regulator

Assembly to the Regulator Mounting Bracket.

b. Remove the hardware securing the Bracket to

the rear panel of the Power Supply.

c. Remove the Mounting Bracket from the Filter/

Regulator Assembly .

d. Transfer the gas input tube from the original

Filter/Regulator Assembly to the replacement
Assembly. Insert the hose into the elbow fit­ting until fully seated. The fitting will auto­matically lock.

NOTE

The Power Supplies use three types of Filter/Regu­lator assembly with mounting bracket. Type A-1
assemblies replace type A assemblies. Refer to the
illustration.

Regulator / Filter Assembly

Type A

A-03326

Type A-1

Type B

1. Disconnect the gas supply hose from the Filter/
Regulator Assembly .

2. Remove the Power Supply cover per Subsection

5.04-A.

3. Disconnect the gas input tube from the Pressure
Switch 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. Replace the Filter/Regulator Assembly as follows:

e. Attach the replacement Regulator/Filter As-

sembly and Mounting Bracket to the rear panel
of the Power Supply with hardware removed
earlier . The gas input tube must pass thr ough
the access opening on the rear of the Power
Supply.

5. To connect the gas input tube to the Pressure
Switch Adapter Fitting, simply insert the hose into
the fitting until fully seated. The fitting will auto­matically lock.

6. Re-install the Power Supply cover.

7. Connect the gas supply hose to the Regulator/Fil­ter. Slowly apply gas pressure to the assembly,
checking for leaks.

B. Filter/Regulator Bracket Replacement

For Power Supplies with Type A Regulator/Filter:

1. Shut off the gas supply at the source. Disconnect
the gas supply hose from the Filter/Regulator As­sembly.

For All Units:

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

For Power Supplies with T ype A or Type A-1 Fil­ter/Regulator:

a. Remove the hardware securing the mounting

bracket to the rear panel of the Power Supply.
Remove the Assembly and Bracket from the
Power Supply.

b. Attach the replacement Regulator/Filter As-

sembly and mounting bracket to the rear panel
of the Power Supply with hardware removed
earlier . The gas input tube (included in the re­placement kit) must pass through the access
opening on the rear of the Power Supply.

Manual 0-2806 5-7 REPAIRS & REPLACEMENT PROCEDURES

3. Remove the hardware securing the Regulator
Mounting Bracket to the Rear Panel. Remove the
Bracket.

4. Positionthe replacement bracket and secure it with
the hardware removed previously.

5. Secure the Filter/Regulator Assembly to the Regu­lator Mounting Bracket with the nut removed pre­viously.

For Power Supplies with Type A Regulator/Filter:

6. Re-connect the gas supply hose to the Filter/Regu­lator Assembly. Slowly apply gas pressure to the
assembly, checking for leaks.

C. Standard Filter Element Replacement

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

D. Optional Single-Stage Filter Element

Replacement

NOTES

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

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

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

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

6. Reinstall the bowl.

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

Regulator/Filter Assembly

(Type A)

(Type A-1)

(Type B)

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

1. Remove power from power supply.

2. Disconnect gas supply hose.

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

Assembled Filter

Cover

Baffle Ring

Filter Element
Spring

Spool

Bowl

A-03325

Barbed

Fitting

A-02476

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

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

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

6. Replace Housing on Cover .

7. Attach gas supply hose.

NOTE

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

REPAIRS & REPLACEMENT PROCEDURES 5-8 Manual 0-2806

E. Optional Two-Stage Filter Element

Replacement

NOTE

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

1. Remove power from power supply.

WARNING

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

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

F. Input Power Cable Replacement

1. Remove the cover per Subsection 5.04-A.

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

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

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

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

For 208/230-Volt Power Supplies:

White Input
Cable (L1)

Blue
Wire #3

Blue
Wire #12

Black
Cable #2

T1

First & Second
Stage
Cartridges
(as marked)

A-02942

3. Slide out the old Filter Elements.

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

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

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

Blue
Wire #4

Black Input
Cable (L2)

A-02849

Blue
Wire #11

Label

Black
Cable #1

For 400-Volt and 460-Volt Power Supplies:

To E2

To E3

Connections to

Main PCB

To E1

T1 T2 T3

L1 L2 L3

Input Side

L3

L2

T2

Label

Manual 0-2806 5-9 REPAIRS & REPLACEMENT PROCEDURES

L1

#12

#3

#11

#4

Main Contactor

A-03176

5.08 Right Side Internal Parts
Replacement

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

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

7. Replace the power supply cover.

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 V alve are one Assembly .

1. Remove the cover per Subsection 5.04-A.

2. Disconnect:
a. Wire #9 and wire #10 from the Pr essure Switch

Assembly.

b. Wir e #7 and wire #8 from the Solenoid Assem-

bly.

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

B. CD PC Board Assembly Replacement

CAUTION

The Power Supplies use two types of CD PC Board.
Refer to the Parts List and Appendix Pages for
proper identification.

Follow the antistatic procedures in Subsection 5.02.

1. Remove the cover per Subsection 5.04-A.

2. Disconnect the wiring connections to the CD PC
Board Assembly, noting the location of each con­nection.

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

4. Install the replacement CD PC Board Assembly by
reversing the above steps.

C. Fan Replacement (M1)

1. Remove the cover per Subsection 5.04-A.

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

Dislodge Solenoid
Assembly

Push Clip

to the left to

release Solenoid

Assembly

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

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

A-02854

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

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

5. Install the replacement Fan Assembly as follows:
a. Position Fan with the label facing inward and

the Fan terminals facing bottom right.

b. Connect the two wire connectors to the two Fan

terminals.

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

Shroud first, then the left.

NOTE

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

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

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

REPAIRS & REPLACEMENT PROCEDURES 5-10 Manual 0-2806

D. Main Transformer Replacement (T5)

CAUTION

The Power Supplies use two types of Main Trans­former . Refer to the Parts Lists for proper identifi­cation.

The Main T ransformer is located behind the Fan Shr oud.
For access to the Main T ransformer , remove the Bulkhead
and Solenoid/Pressure Switch Assembly and the Fan and
Fan Shroud.

1. Remove the cover per Subsection 5.04-A.

2. Release the tab on the Fan Shroud that secures the
Bulkhead in position. Pull the Bulkhead upwards
so the Bulkhead tabs are released from the slots
on the Center Chassis.

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

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

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

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

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

8. Label and disconnect cables at the following
points on the Main Power PC Board. See Appen­dix 10-A, 10-B, 10-C, or 10-D.

Main P C B oard Connect i on P oi nt s

208/230V

Power Supply

E3, E4, E8, E9 E35, E4, E8, E9

9. Disconnect wires E1 & E2 from the CD PC Board.
Refer to Appendix 5-A or 5-B.

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

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

400V, 460V

Power Supply

12. Turn unit onto its left side.

13. Position the replacement T ransformer as follows:
a. with the PC Board facing out from the unit;
b. the cables oriented to the right side;
c. the four Transformer Rubber Feet well seated

in the four holes in the Center Chassis.

14. Feed the Transformer wir es and cables as follows:
a. White Transformer Cable - feed through bot-

tom hole in Center Chassis.

b. Black Transformer Cable - feed through hole

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

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

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

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

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

17. Connect wire connector to the Coil Winding on the
Main T ransformer.

18. Reinstall the Bulkhead.

19. Reinstall the Pressure Switch/Solenoid Assembly.

20. Reinstall the Fan per Subsection 5.08-C and recon­nect the wiring.

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

Main P C B oard Connect i on P oi nt s

208/230V

Power Supply

E3, E4, E8, E9 E35, E4, E8, E9

400V, 460V

Power Supply

22. Reconnect wires E1 & E2 to the CD PC board.

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

E. Output Inductor Assembly Replacement (L1)

1. Remove the cover per Subsection 5.04-A.

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

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

Manual 0-2806 5-11 REP AIRS & REPLA CEMENT PR OCEDURES

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

6. Install the replacement CD T ransformer as follows:

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

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

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

a. The Output Inductor wires should be oriented

towards the front of the unit.

b. If a magnetic socket is unavailable, use a piece

of tape instead. This will help keep the nut
from falling out of the socket when reinstall­ing the nut.

F . CD Transf ormer Replacement

1. Locate the CD PC Board Assembly. Disconnect
wires from E1 and E2. Refer to Appendix 5-A or
5-B.

WARNING

DO NOT allow the CD T ransformer wires to touch
anything metal.

a. Attach the brass terminal ring to the Bulkhead

Adapter Fitting with the brass jam nut. Make
sure the wires do not contact anything metal.
The CD PC Board may vary from that shown
in the following illustration:

2. Remove the two long screws securing the CD
T ransformer Assembly to the Fan Shroud. Set the
Ferrite U-Cores aside.

WARNING

The Ferrite U-Cores are very brittle and can be
damaged easily if not handled properly.

3. Disconnect:
a. the black CD Transformer wire from Connec-

tor E10 on the Main Power PC Board.

b. red pilot return wire #32 from the Pilot Relay

Assembly.

c. Reroute both back through the Center Chassis

and Bulkhead. Refer to Appendix 10-A, 10-B,
or 10-C.

4. Disconnect the gas tube from the Bulkhead
Adapter Fitting. Press against the ring of the Fit­ting while gently pulling on the tube.

5. Remove the large brass jam nut securing the large
terminal ring to the Bulkhead Adapter Fitting, then
remove the terminal ring.

A-02938

Keep wire away
from all metal parts.

b. Reinstall the short black gas hose in the Adapter

Fitting.

c. Place the CD Transformer Assembly in the cor-

rect orientation. Secure it on the Fan Shroud

with the two long screws.
d. Connect wires to E1 & E2 on the CD PC Board.
e. T wist the red pilot return wire #32 and the black

CD Transformer wire together 6-8 times.

Thread both through the Bulkhead and through

the bottom hole in the center Chassis.
f. Reconnect pilot return wire to Pilot Relay As-

sembly . Reconnect black CD T ransformer wir e

to E10 on the Main Power PC Board.

This concludes the replacement procedur es.

REPAIRS & REPLACEMENT PROCEDURES 5-12 Manual 0-2806

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

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

Section 6.03 Major External Replacement Parts
Section 6.04 Front Panel Replacement Parts
Section 6.05 Left Side Internal Replacement Parts
Section 6.06 Right Side Internal Replacement Parts
Section 6.07 Rear Panel Replacement Parts
Section 6.08 Options and Accessories

NOTE

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

B. Returns

If a product must be returned for service, contact your
distributor. Materials returned without proper authori­zation will not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and complete
description of the part or assembly, as listed in the parts
list for each type item. Also include the model and serial
number of the torch. Addr ess all inquiries to your autho­rized distributor .

Manual 0-2806 6-1 P A RTS LISTS

6.03 Major External Replacement Parts

Item # Qty Description Catalog #

1 1 Cover with labels 9-8535
2 1 T ube, roll handle 9-8520

Hardware:

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

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

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

1

A

NOTES

B,C

2

A-02819

1. May be purchased locally.

2. Illustration may vary slightly from unit.

PARTS LISTS 6-2 Manual 0-2806

6.04 Front Panel Replacement Par ts

Item# Qty Description Catalog #

1 1 Knob, Fluted, Skirted, 0.250 I.D. 9-8527
2 1 On/Off Rocker Switch, DPST 8-3258
3 1 Run/Set Switch, Rocker , SPST 9-1042
4 1 Assembly, Pot/LED PCB 9-8004
5 1 Cable, Work, #6 awg with Clamp, 20 Ft (6.1 m) 9-8528

1

4

3

NOTE

2

A-02850

5

Illustration may vary slightly from unit.

Manual 0-2806 6-3 P A RTS LISTS

6.05 Left Side Internal Replacement Parts

Item # Qty Description Ref Catalog #

1 Fuse F1

1 1/2A, 250V (For 208/230-Volt units) 9-6395
1 1/2A, 600V (For 400-Volt and 460-Volt units) 9-8110

Main Input Contactor W1

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

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

3 1 PCR Pilot Relay (May mount to front panel) PCR 9-7508
4 1 PCB Assembly , Logic 9-8536
5 1 PCB Kit, IGBT Circuit 9-8540

1 Round Thermal pad

6 1 PCB Kit, Output Diode 9-8539

1 Round Thermal pad

7 PCB Kit, Input Diode

1 For 208/230-Volt Units 9-8538
1 For 400-Volt and 460-Volt Units 9-8551
1 Rectangular Thermal Pad
1 Solid Disk
1 Round Thermal Pad
1 Screw, 8-32 x 1", PPH, with external star washer

8 PCB Kit, Main Power

1 For 208/230-Volt Units with 4" x 7" (102 mm x 178 mm) CD PCB 9-8537
1 For 208/230-Volt Units with 3.5" x 4" (89 mm x 102 mm) CD PCB 9-8605
1 For 400-Volt Units 9-8550
1 For 460-Volt Units 9-8555

Hardware:

A 4 Hex nut See Note

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

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

NOTE

May be purchased locally.

PARTS LISTS 6-4 Manual 0-2806

7

C, D

8

E

1

5

4

6

B,C

B,C

A

OR

2B

2A

A

3

A-02936

NOTE

Illustration may vary slightly from unit.

Manual 0-2806 6-5 P A RTS LISTS

6.06 Right Side Internal Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Assembly, Pressure Switch/Solenoid M2 9-8563

2 1 Assembly, CD PCB

For 208/230-Volt Units with 4" x 7" (102 mm x 178 mm) CD PCB 9-8541
For 208/230-Volt Units with 3.5" x 4" (89 mm x 102 mm) CD PCB 9-8552

For 400-Volt and 460-Volt Units 9-8552
3 1 Fan, 220V, 115 CFM M1 9-7687
4 1 Assembly, Main Transformer T5

For 208/230-Volt Units with 4" x 7" (102 mm x 178 mm) CD PCB 9-8542

For 208/230-Volt Units with 3.5" x 4" (89 mm x 102 mm) CD PCB 9-8564

For 400-Volt and 460-Volt Units 9-8564
5 1 Assembly, Output Inductor L1 9-8560
6 1 Coil, CD T ransformer, Secondary T1 9-8543

Hardware:

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

B 1 #10 External star washer See Note

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

E 4 6-32 x 3/8" pph screw See Note
F 2 6-32 x 3-1/2" pph screw See Note

G 1 1/4" External star washer See Note
H 1 1/4-20 X 1" hex bolt, brass See Note

NOTE

May be purchased locally.

PARTS LISTS 6-6 Manual 0-2806

2

E

H

C, G

A

F

1

6

A, B

3

D

4

A

A-02855

NOTE

Illustration may vary slightly from unit.

Manual 0-2806 6-7 P A RTS LISTS

5

6.07 Rear Panel Replacement Parts

Item # Qty Description Catalog #

Assembly , Regulator/Filter
1 1 Regulator/Filter Assembly type A-1 incl. Bracket (Refer to Note 3) 9-8524
2 1 Regulator/Filter Assembly (only) 9-7514
3 1 Regulator Mounting Nut (only) 9-5804

Regulator Mounting Bracket (only)
4 1 For Units with T ype A Assembly 9-8521
5 1 For Units with Type A-1 Assembly 9-8606
6 1 For Units with Type B Assembly 9-7589
7 1 Regulator/Filter Replacement Element (T ype A Regulator/Filter Assembly) 9-8534
8 1 Regulator/Filter Replacement Element (T ype A-1 and Type B 9-4414

Regulator/Filter Assembly)

9 1 Pressure Gauge 9-1045

10 1 Input Power Cable

For 208/230-Volt Units 8-4384
For 400-Volt Units 9-8562
For 460-Volt Units 9-8593

Hardware:

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

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

Regulator/Filter Assembly

Type A

A

4

7

Regulator/Filter Assembly

1

A

5

9

Type A-1

2

3

8

Regulator/Filter Assembly

6

B

9

Type B

2

3

8

NOTES

1. May be purchased locally .

2. Illustration may vary slightly from unit.

3. Catalog number 9-8524 is a complete T ype A-1 assem­bly with bracket and replaces original Type A assem­blies. Complete Type A assemblies are not available.

PARTS LISTS 6-8 Manual 0-2806

10

A-03328

6.08 Options and Accessories

Qty Description Catalog #

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

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

The following are not shown:

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

Single-Stage

Filter Kit

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

Cover

Barbed

Fitting

Wheel Kit, Installed

Assembled Filter

A-02476

Two-Stage

Filter Kit

First & Second
Stage
Cartridges
(as marked)

A-02942

Manual 0-2806 6-9 P A RTS LISTS

A-02958

PARTS LISTS 6-10 Manual 0-2806

APPENDIX 1: INPUT WIRING REQUIREMENTS

Input Power Inpu t Current Input Suggested Sizes (See N ote s )

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 60 9 42 60 10 10
230 60 9 37 60 10 10
400 50 8 11 15 12 12
400 60 8.5 12 15 12 12
460 60 8 10 15 12 12
4606014 17.5 25 12 12

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electrical Code

NOTES

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations

refer to local or national codes.
Cable conductor temperature used is 167° F (75° C).
An energy limiting fuse UL Class RK-1 (examples: BUSS LPS/LPN-RK or Gould-Shawmut AZK-A6K) should be

used to minimize damage to Plasma Cutting, Welding or power distribution equipment.
NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.

Manual 0-2806 A-1 APPENDIX

APPENDIX 2: SEQUENCE OF OPERATION (BLOCK

DIAGRAM)

ACTION

Close external

disconnect switch.

RESULT

Power to system.

ACTION

Protect eyes and

activate torch.

RESULT

Gas flows (2 seconds).

After gas pre-flow:

DC indicator on.

Pilot relay closes.

Pilot arc established

ACTION

ON/OFF switch

to ON.

RESULT

AC indicator blinks for 8
seconds then steady on.

Fans on.

Power circuit ready.

gas flows to set pressure.

PILOT ARC

ACTION

RUN/SET switch

to SET.

RESULT

Gas solenoid open,

GAS indicator on.

ACTION

RUN/SET

switch to RUN.

RESULT

Gas flow stops.

GAS indicator off.

ACTION

Torch moved away

from work (while

still activated).

RESULT

Main arc stops.

Pilot arc automatically

restarts.

ACTION

Torch deactivated (by torch switch

release or by remote device).

RESULT

(Power supply enable signal removed)

post-flow, pilot arc will immediately restart.

(1/4 in/6.4mm) of workpiece, main arc

Gas solenoid closes, gas flow stops.

Main arc stops.

Gas flows (10 seconds)

NOTE - If torch is activated during

If torch is within transfer distance

will transfer.

After post-flow:

GAS indicator off.

ACTION

ON/OFF switch

to OFF

RESULT

All indicators off.

Power supply fans off.

ACTION

Torch moved within

transfer distance of workpiece.

RESULT

Main arc transfer.

Pilot arc off.

ACTION

Open external

disconnect.

RESULT

No power to system.

A-02778

APPENDIX A-2 Manual 0-2806

APPENDIX 3-A: LOGIC PC BOARD LAYOUT (For Rev AA

Logic Boards)

TP3

TP8

Pins P1-1
to P1-36

D19

TP2

Logic Board Signals

P1-1 +12vdc from Main PCB
P1-2 +12vdc from Main PCB
P1-3 Ground
P1-4 Ground
P1-5 Logic Low - W1 on Signal
P1-6 Not used
P1-7 RUN/SET Signal Logic Low for SET
P1-8 Logic Low = Pressure good signal
P1-9 Overtemp Signal (Logic Low)
P1-10 Logic Low = Inrush Done Signalfrom Main PCB
P1-11 Logic Low = Signal CD Enable from Main PCB
P1-12 Logic Low = Signal CD Enable from Main PCB
P1-13 Not Used
P1-14 Logic Low = Gas on Signal to Main PCB
P1-15 Logic Low = CSR Signal from Main PCB
P1-16 Logic Low = Pilot on Signal to Main PCB
P1-17 Logic Low = DC OK Signal to Main PCB
P1-18 Logic Low = OVERTEMP Signal to Main PCB
P1-19 Logic Low = AC OK Signal to Main PCB
P1-20 Return for Torch Switch
P1-21 Logic Low = Torch Switch Signal
P1-22 +12 vdc
P1-23 To Current Control Pot
P1-24 Current Control
P1-25 Current Control Return

TP7

TP1

TP4

TP9

TP10

TP5

D7

TP6

P1-26 Gate Drive B Return
P1-27 Gate Drive B Signal
P1-28 Gate Drive A Return
P1-29 Gate Drive A Signal
P1-30 (-) Output Signal
P1-31 Current Sense Signal
P1-32 Current Sense Signal

TP1 Logic Ground
TP2 Gate Drive Return
TP3 PWM Fault Shutdown (Logic Low = fault)
TP4 CSR Signal (Logic Low = CSR)
TP5 Demand Signal
TP6 Gate Drive B Signal
TP7 Gate Drive A Signal
TP8 Fault Signal (from torch switch, overtemp,

gas pressure)
TP9 (-) Output Signal
TP10 DC OK Signal (jumper to TP1 to override)

INDICA T OR LEDs:
D7 Inverter On
D19 CD Enable

A-02779

Manual 0-2806 A-3 APPENDIX

APPENDIX 3-B: LOGIC PC BOARD LAYOUT (For Rev AB

Boards or Later)

TP4

P1-1 to P1-36

TP5

D16

TP8

TP9

Logic Board Signals

P1-1 +12vdc from Main Power PCB
P1-2 +12vdc from Main PCB
P1-3 Ground
P1-4 Ground
P1-5 Logic Low = W1 ON signal
P1-6 Not used
P1-7 RUN/SET Signal Logic Low for SET
P1-8 Logic Low = PS1 Pr essure Switch closed =

Pressure OK
P1-9 Logic Low = TS1 Closed=OVER TEMP
P1-10 Logic Low = Inrush done signal
P1-11 Logic Low = signal CD enable
P1-12 Logic Low = signal CD enable
P1-13 Not Used
P1-14 Logic Low = Gas ON signal to Main PCB
P1-15 Logic Low = CSR signal from Main PCB
P1-16 Logic Low = Pilot ON signal to Main PCB
P1-17 Logic Low = DC OK signal to Main PCB
P1-18 Logic Low = OVERTEMP signal to Main PCB
P1-19 Logic Low = AC OK signal
P1-20 Return for torch switch
P1-21 Logic Low = torch switch signal
P1-22 +12 VDC
P1-23 To Current Control Pot
P1-24 Current Control
P1-25 Current Control Return

TP1

TP2 TP3

TP10

TP6

D13

TP7

P1-26 Gate Drive B Return
P1-27 Gate Drive B Signal
P1-28 Gate Drive A Return
P1-29 Gate Drive A Signal
P1-30 (-) Output Signal
P1-31 Current Sense Signal
P1-32 Current Sense Signal

TP1 Logic Ground
TP2 CSR Signal (Logic Low = CSR)
TP3 DC OK Signal (jumper to TP1 to override)
TP4 PWM Fault Shutdown (Logic Low = fault)
TP5 Fault Signal (from torch switch, overtemp,

gas pressure)
TP6 Demand Signal
TP7 Gate Drive B Signal
TP8 Gate Drive A Signal
TP9 Gate Drive Return
TP10 (-) Output Signal

INDICA T OR LEDs:
D13 Inverter On
D16 CD Enable

A-02937

APPENDIX A-4 Manual 0-2806

This page left blank.

Manual 0-2806 A-5 APPENDIX

APPENDIX 4-A: MAIN POWER PC BOARD LAYOUT (for

208/230-Volt units with Boards to Rev. G)

E1

E2

E12

INPUT
DIODE
PCB

E11

E3

E4

LT1

J26

TP10

TP18

TP2

IGBT
CIRCUIT
PCB

J4

J5

TP1

J2

J23

OUTPUT
DIODE
PCB

J3

TP5

J1

J22
E18

J9

A-02767

E13

Main Power PC Board Signals

J1-1 +12vdc to Logic PCB
J1-2 +12vdc to Logic PCB
J1-3 Ground
J1-4 Ground
J1-5 Logic Low = - W1 on Signal
J1-6 Not used
J1-7 RUN/SET Signal Logic Low for SET
J1-8 Logic Low = PS1 Closed=Pressure OK

to Logic PCB
J1-9 Logic Low = TS1 (or TS2) Closed=Overtemp
J1-10 Logic Low = Inrush done signal to Logic PCB
J1-11 Logic Low = Signal CD enable to Logic PCB
J1-12 Logic Low = Signal CD enable to Logic PCB
J1-13 Not Used
J1-14 Logic Low = Gas on Signal from Logic PCB
J1-15 Logic Low = CSR Signal to Logic PCB

APPENDIX A-6 Manual 0-2806

E15

E7

E19

E8

E21

E20

E9

E10

J1-16 Logic Low = Pilot on Signal from Logic PCB
J1-17 Logic Low = DC OK Signal from Logic PCB
J1-18 Logic Low = OVERTEMP signal from Logic PCB
J1-19 Logic Low = AC OK signal from Logic PCB
J1-20 Return for torch switch
J1-21 Logic Low = torch switch signal to Logic PCB
J1-22 +12 vdc to Logic PCB
J1-23 To Current Control Pot from Logic PCB
J1-24 Current Control to Logic PCB
J1-25 Current Control Return from Logic PCB
J1-26 Gate Drive B Return from Logic PCB
J1-27 Gate Drive B Return from Logic PCB
J1-28 Gate Drive A Return from Logic PCB
J1-29 Gate Drive A Return from Logic PCB
J1-30 Not used.
J1-31 Not used.

J1-32 Not used.
J1-33 Not used.
J1-34 Not used.
J1-35 Ground
J1-36 Ground

J2-1 Overtemp Signal from TS1 mounted on Heatsink
J2-2 Overtemp Return
J3-1 Pilot ON Signal Logic Low for Pilot ON
J3-2 +18 vdc to PCR Pilot Relay
J3-3 28VAC B from Auxilliary Transformer to On/OFF Switch
J3-4 28VAC A from Auxilliary Transformer to ON/OFF Switch
J3-5 28VAC A from ON/OFF Switch to Main PC Board
J3-6 28VAC B from ON/OFF Switch to Main PC Board
J3-7 RUN/SET Signal Logic Low Logic Low=SET Mode
J3-8 RUN/SET Return

J4-1 28V AC A to Gas Solenoid
J4-2 28VAC B to Gas Solenoid
J4-3 Pressure SwitchSignal Logic Low
J4-4 Pressure SwitchSignal Return Low
J4-5 28VAC Main Contactor W1
J4-6 28VAC to Main Contactor W1
J4-7 CD Enable Signal Return
J4-8 Logic Low=CD Enable Signal Logic Low

J5-1 28V AC A - for test only
J5-2 28VAC Return - for test only
J5-3 28VAC B for test only

J8-1 230VAC from Primary of Aux T ransformer Fan Power
J8-4 230VAC from Primary of Aux T ransformer Fan Power

J9-1 Torch Switch Return
J9-3 Tor ch Switch

J23-1 Overtemp Signal from TS2 mounted in Output Inductor
J23-2 Overtemp Return

J26-1 Primary Power to Auxillary Transformer
J26-4 Primary Power to Auxillary Transformer

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

L T1 Power ON Indicator (indicates power is present on the line side of the Input Contactor)

Manual 0-2806 A-7 APPENDIX

APPENDIX 4-B: MAIN POWER PC BOARD LAYOUT (for

208/230-Volt units with Boards Rev. H and I)

E1

E2

E12

INPUT

DIODE

PCB

E11

E3

E4

J8

LT1

IGBT
CIRCUIT
PCB

J26

TP10

TP18

TP2

J4

J5

TP1

J2

OUTPUT

DIODE

PCB

J23

J3

TP5

J1

J22

E18

J9

E5

E16

H

A-03032

E13

E15

Main Power PC Board Signals

J1-1 +12vdc to Logic PCB
J1-2 +12vdc to Logic PCB
J1-3 Ground
J1-4 Ground
J1-5 Logic Low =- W1 on Signal
J1-6 Not used
J1-7 RUN/SET Signal Logic Low for SET
J1-8 Logic Low = PS1 Closed=Pressure OK

to Logic PCB
J1-9 Logic Low = TS1 (or TS2) Closed=Overtemp
J1-10 Logic Low = Inrush done signal to Logic PCB
J1-11 Logic Low = Signal CD enable to Logic PCB
J1-12 Logic Low = Signal CD enable to Logic PCB
J1-13 28VAC-A
J1-14 Logic Low = Gas on Signal from Logic PCB
J1-15 Logic Low = CSR Signal to Logic PCB

E34

E7

E19

E21

E20

E17

E10

J1-16 Logic Low = Pilot on Signal from Logic PCB
J1-17 Logic Low = DC OK Signal from Logic PCB
J1-18 Logic Low = OVERTEMP signal from Logic PCB
J1-19 Logic Low = AC OK signal from Logic PCB
J1-20 Return for torch switch
J1-21 Logic Low = torch switch signal to Logic PCB
J1-22 +12 vdc to Logic PCB
J1-23 To Current Control Pot from Logic PCB
J1-24 Current Control to Logic PCB
J1-25 Current Control Return from Logic PCB
J1-26 Gate Drive B Return from Logic PCB
J1-27 Gate Drive B Return from Logic PCB
J1-28 Gate Drive A Return from Logic PCB
J1-29 Gate Drive A Return from Logic PCB
J1-30 Negative out
J1-31 Current Sense-A

E6

APPENDIX A-8 Manual 0-2806

J1-32 Current Sense-A.
J1-33 Current Sense-B.
J1-34 Current Sense-B.
J1-35 Ground
J1-36 Ground

J2-1 Overtemp Signal from TS1 mounted on Heatsink
J2-2 Overtemp Return

J3-1 Pilot ON Signal Logic Low for Pilot ON
J3-2 +18 vdc to PCR Pilot Relay
J3-3 28VAC B from Auxilliary Transformer to On/OFF Switch
J3-4 28VAC A from Auxilliary Transformer to ON/OFF Switch
J3-5 28VAC A from ON/OFF Switch to Main PC Board
J3-6 28VAC B from ON/OFF Switch to Main PC Board
J3-7 RUN/SET Signal Logic Low Logic Low=SET Mode
J3-8 RUN/SET Return

J4-1 28V AC A to Gas Solenoid
J4-2 28VAC B to Gas Solenoid
J4-3 Pressure Switch Signal Logic Low
J4-4 Pressure Switch Signal Return Low
J4-5 28VAC Main Contactor W1
J4-6 28VAC to Main Contactor W1
J4-7 CD Enable Signal Return
J4-8 Logic Low=CD Enable Signal Logic Low

J5-1 28V AC A - for test only
J5-2 28VAC Return - for test only
J5-3 28VAC B for test only

J8-1 230VAC from Primary of Auxillary T ransformer Fan Power
J8-4 230VAC from Primary of Auxillary T ransformer Fan Power

J9-1 Torch Switch Return
J9-3 Tor ch Switch

J23-1 Overtemp Signal from TS2 mounted on Output Inductor
J23-2 Overtemp Return

J26-1 Primary Power to Auxillary Transformer
J26-4 Primary Power to Auxillary Transformer

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

L T1 Power ON Indicator (indicates power is present on the line side of the Input Contactor)

Manual 0-2806 A-9 APPENDIX

APPENDIX 4-C: MAIN POWER PC BOARD LAYOUT (for

208/230-Volt units with Boards Rev. J)

E1

E2

E22 E23

E26

E27

E12

E24

E11

E25

E3

E4

LT1

J8

J26

TP10

TP18

J6

J7

TP2

J4

J5

J27 (Refer
to NOTE)

TP1

E42 E43

J2

E36 E37

J23

R8
R9
R11
R13
R85

R85 (Refer
to NOTE)

J3

TP5

J1

J22

E18

J9

E5

E28 E29

J

A-03270

E13

TP-14

E15

TP-13

J21

J20

Main Power PC Board Signals

J1-1 +12vdc to Logic PCB
J1-2 +12vdc to Logic PCB
J1-3 Ground
J1-4 Ground
J1-5 Logic Low =- W1 on Signal
J1-6 Not used
J1-7 RUN/SET Signal Logic Low for SET
J1-8 Logic Low = PS1 Closed=Pressure OK

to Logic PCB
J1-9 Logic Low = TS1 (or TS2) Closed=Overtemp
J1-10 Logic Low = Inrush done signal to Logic PCB
J1-11 Logic Low = Signal CD enable to Logic PCB
J1-12 Logic Low = Signal CD enable to Logic PCB
J1-13 28VAC-A

E34

E7

E39 E38

E19

E21

E40 E41

E20

E17

J1-14 Logic Low = Gas on Signal from Logic PCB
J1-15 Logic Low = CSR Signal to Logic PCB
J1-16 Logic Low = Pilot on Signal from Logic PCB
J1-17 Logic Low = DC OK Signal from Logic PCB
J1-18 Logic Low = OVERTEMP signal from Logic PCB
J1-19 Logic Low = AC OK signal from Logic PCB
J1-20 Return for torch switch
J1-21 Logic Low = torch switch signal to Logic PCB
J1-22 +12 vdc to Logic PCB
J1-23 T o Curr ent Contr ol Pot from Logic PCB
J1-24 Current Control to Logic PCB
J1-25 Current Control Return from Logic PCB
J1-26 Gate Drive B Return from Logic PCB
J1-27 Gate Drive B Return from Logic PCB

E16

E6

E10

APPENDIX A-10 Manual 0-2806

J1-28 Gate Drive A Return from Logic PCB
J1-29 Gate Drive A Return from Logic PCB
J1-30 Negative out
J1-31 Current Sense-A
J1-32 Current Sense-A.
J1-33 Current Sense-B.
J1-34 Current Sense-B.
J1-35 Ground
J1-36 Ground

J2-1 Overtemp Signal from TS1 mounted on Heatsink
J2-2 Overtemp Return

J3-1 Pilot ON Signal Logic Low for Pilot ON
J3-2 +18 vdc to PCR Pilot Relay
J3-3 28VAC B from Auxilliary Transformer to On/OFF Switch
J3-4 28VAC A from Auxilliary Transformer to ON/OFF Switch
J3-5 28VAC A from ON/OFF Switch to Main PC Board
J3-6 28VAC B from ON/OFF Switch to Main PC Board
J3-7 RUN/SET Signal Logic Low Logic Low=SET Mode
J3-8 RUN/SET Return

J4-1 28V AC A to Gas Solenoid
J4-2 28VAC B to Gas Solenoid
J4-3 Pressure Switch Signal Logic Low
J4-4 Pressure Switch Signal Return Low
J4-5 28VAC Main Contactor W1
J4-6 28VAC to Main Contactor W1
J4-7 CD Enable Signal Return
J4-8 Logic Low=CD Enable Signal Logic Low

J5-1 28V AC A - for test only
J5-2 28VAC Return - for test only
J5-3 28VAC B for test only

J8-1 230VAC from Primary of Auxillary T ransformer Fan Power
J8-4 230VAC from Primary of Auxillary T ransformer Fan Power

J9-1 Torch Switch Return
J9-3 Tor ch Switch

J23-1 Overtemp Signal from TS2 mounted on Output Inductor
J23-2 Overtemp Return

J26-1 Primary Power to Auxillary Transformer
J26-4 Primary Power to Auxillary Transformer
TP1 Logic Ground
TP2 Not Used
TP5 +12vdc
TP10 Current Sense Signal Return
TP18 Current Sense Signal Return
L T1 Power ON Indicator (indicates power is present on the line side of the Input Contactor)

NOTE

Boards for use with 19x1751 (3.5" x 4") CD PCB include R85. Do not install shorting connector in J27.
Boards for use with 19x1729 (4" x 7") CD PCB omit R85. Install shorting connector in J27. Refer to Section 6 for catalog

numbers.

Manual 0-2806 A-11 APPENDIX

APPENDIX 4-D: MAIN POWER PC BOARD LAYOUT (for

400-Volt and 460-Volt units )

J5

J4

TP1

J2

J23

J3

Assembly No. 19x1743 AA

LT1

J8

J26

TP10

TP18

J7

J6

TP5

J1

J22

TP2

E12
E11

E35

E4

J20

TP13

TP14

A-03043

E13 E15

Main Power PC Board Signals

J1-1 +12vdc to Logic PCB
J1-2 +12vdc to Logic PCB
J1-3 Ground
J1-4 Ground
J1-5 Logic Low =- W1 on Signal
J1-6 Not used
J1-7 RUN/SET Signal Logic Low for SET
J1-8 Logic Low = PS1 Closed = Pressure OK

to Logic PCB
J1-9 Logic Low = TS1 (or TS2) Closed=Overtemp
J1-10 Logic Low = Inrush done signal to Logic PCB
J1-11 Logic Low = Signal CD enable to Logic PCB
J1-12 Logic Low = Signal CD enable to Logic PCB
J1-13 28VAC-A
J1-14 Logic Low = Gas on Signal from Logic PCB
J1-15 Logic Low = CSR Signal to Logic PCB

J21

E45

E19

E7

E34

E8

E21

E20

E17

E9

J1-16 Logic Low = Pilot on Signal from Logic PCB
J1-17 Logic Low = DC OK Signal from Logic PCB
J1-18 Logic Low = OVERTEMP signal from Logic PCB
J1-19 Logic Low = AC OK signal from Logic PCB
J1-20 Return for torch switch
J1-21 Logic Low = torch switch signal to Logic PCB
J1-22 +12 vdc to Logic PCB
J1-23 T o Curr ent Control Pot from Logic PCB
J1-24 Current Control to Logic PCB
J1-25 Current Control Return from Logic PCB
J1-26 Gate Drive B Return from Logic PCB
J1-27 Gate Drive B Return from Logic PCB
J1-28 Gate Drive A Return fr om Logic PCB
J1-29 Gate Drive A Return fr om Logic PCB
J1-30 Negative out
J1-31 Current Sense-A

J9

E18

E5

E16

E6

E10

APPENDIX A-12 Manual 0-2806

J1-32 Current Sense-A.
J1-33 Current Sense-B.
J1-34 Current Sense-B.
J1-35 Ground
J1-36 Ground

J2-1 Overtemp Signal from TS1 mounted on Heatsink
J2-2 Overtemp Return

J3-1 Pilot ON Signal Logic Low for Pilot ON
J3-2 +18 vdc to PCR Pilot Relay
J3-3 28VAC B from Auxilliary Transformer to On/OFF Switch
J3-4 28VAC A from Auxilliary Transformer to ON/OFF Switch
J3-5 28VAC A from ON/OFF Switch to Main PC Board
J3-6 28VAC B from ON/OFF Switch to Main PC Board
J3-7 RUN/SET Signal Logic Low Logic Low=SET Mode
J3-8 RUN/SET Return

J4-1 28V AC A to Gas Solenoid
J4-2 28VAC B to Gas Solenoid
J4-3 Pressure Switch Signal Logic Low
J4-4 Pressure Switch Signal Return Low
J4-5 28VAC Main Contactor W1
J4-6 28VAC to Main Contactor W1
J4-7 CD Enable Signal Return
J4-8 Logic Low=CD Enable Signal Logic Low

J5-1 28V AC A - for test only
J5-2 28VAC Return - for test only
J5-3 28VAC B for test only

J8-1 230VAC from Primary of Auxilliary T ransformer Fan Power
J8-4 230VAC from Primary of Auxilliary T ransformer Fan Power

J9-1 Torch Switch Return
J9-3 Tor ch Switch

J23-1 Overtemp Signal from TS2 mounted on Output Inductor
J23-2 Overtemp Return

J26-1 Primary Power to Auxillary Transformer
J26-4 Primary Power to Auxillary Transformer

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

L T1 Power ON Indicator (indicates power is present on the line side of the Input Contactor)

Manual 0-2806 A-13 APPENDIX

APPENDIX 5-A: CD PC BOARD LAYOUT (for 208/230-Volt

units through Unit Rev AL)

19x1729

A-03329

E2

E1

TP2

TP1

J11-1
J11-3
J11-4

J11-5

TP3

CD PC Board Signals

J11-1 Approx 36 VAC from Main Switching Transformer. Refer to NOTES.
J11-2 Return
J11-3 Approx 36 VAC from Main Switching Transformer. Refer to NOTES.
J11-4 Logic Low CD Enable Signal from Logic Board (J5-4)
J11-5 Return for CD Enable Signal from Logic PC Board (J5-5)
J11-6 Not Used
J11-7 Not Used
J11-8 Not Used

TP1 Logic Ground
TP2 +12 vdc
TP3 Not Used

E1 CD Output
E2 CD Output

NOTES

1. Actual size is 4" x 7" (102 x 178 mm).

2. Must be read with an oscilloscope.

3. 20 kHz switching frequency.

APPENDIX A-14 Manual 0-2806

APPENDIX 5-B: CD PC BOARD LAYOUT (for 400-Volt and

460-Volt units, and 208/230-Volt units Rev AM and later)

E1

E2

CD PC Board Signals

J28-1 +12 vdc
J28-2 Logic Low CD Enable
J28-3 Not Used
J28-4 Not Used
J28-5 Approx 36VAC from Main Switching Transformer (see NOTES)
J28-6 Not Used
J28-7 Not Used
J28-8 Approx 36VAC from Main Switching Transformer (see NOTES)

J28

8

A-03086

E1 CD Output
E2 CD Output

NOTES

1. Actual size is 3.5" x 4" (89 x 102 mm).

2. Must be read with an oscilloscope.

3. 20 kHz switching frequency.

Manual 0-2806 A-15 APPENDIX

APPENDIX 6: LED/POT PC BOARD LAYOUT

J14

D4

D5

D7

A-01206

Pot/LED PC Board Signals

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

D4 Front Panel AC Indicator

D5 Front Panel TEMP Indicator
D6 Front Panel DC Indicator

D7 Front Panel GAS Indicator

D6

APPENDIX A-16 Manual 0-2806

APPENDIX 7: IGBT CIRCUIT PC BOARD LAYOUT

TP14

E28

E31

A-02851

E30

E29

TP13

E32

E33

Manual 0-2806 A-17 APPENDIX

APPENDIX 8-A: INPUT DIODE PC BOARD LAYOUT

for 208/230-Volt units

E26

E22

E27

E23

E25E24

A-02852

APPENDIX A-18 Manual 0-2806

APPENDIX 8-B: INPUT DIODE PC BOARD LAYOUT

for 400-Volt and 460-Volt units

E44 E23 E22

Assembly No. 19x1743 AA

E26

E27

E24

E25

A-03088

Manual 0-2806 A-19 APPENDIX

APPENDIX 9: OUTPUT DIODE PC BOARD LAYOUT

E39

E42

A-02853

E43

E38

E36

E37

E41

E40

APPENDIX A-20 Manual 0-2806

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

units with Boards Rev. G or earlier)

T o Thermistor

Main PC Board

Input Diode PCB

M1 Fan
Harness

To Input
Contactor

To Main
Transformer
(Primary)

#3

on Heatsink

Solenoid/Pressure
Switch Wire Harness

#4

T o Thermal Protection
Device on
Output
Inductor

ON/OFF
RUN SET
Wire Harness

LED/PCB
Wire
Harness

Torch
Switch

A-02769

#1

#2

To Input
Contactor

IGBT Circuit PCB

Work Lead

Output Diode
PCB

#8

To Main
Transformer
(Secondary)

To Output
Inductor

To PCR
Relay

#9

To CD
Transformer

Manual 0-2806 A-21 APPENDIX

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

units with Boards Rev. H and I)

To Input
Contactor

INPUT
DIODE PCB

Solenoid/Pressure

Switch Wire Harness
M1 Fan
Harness

To Main Trans­former (primary)

#3

IGBT
CIRCUIT
PCB

#4

T o Thermistor
on Heatsink

T o Thermal Protection
Device on Output
Inductor

OUTPUT

DIODE

PCB

ON/OFF
RUN/SET
Wire harness

LED/PCB
Wire
Harness

Torch
Switch

To Output
Inductor

A-03033

#2

#1

To Input
Contactor

APPENDIX A-22 Manual 0-2806

H

Work Lead

#8
To Main Trans-

former (Secondary)

#9

#43

#33

#32

To Bulk­head

To CD

Transformer

To PCR
Relay

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

units with Boards Rev. J)

T o Thermal Protection
Device on Output
Inductor

R85 (Refer
to NOTE)

R8
R9
R11
R13
R85

R22

ON/OFF
RUN/SET
Wire harness

LED/PCB
Wire
Harness

To Input
Contactor

INPUT
DIODE PCB

Solenoid/Pressure
Switch Wire Harness

M1 Fan
Harness

J27 (Refer to NOTE)

T o Thermistor
on Heatsink

A-03271

#2
#1

To Main Trans­former (primary)

#3

IGBT
CIRCUIT
PCB

J

To Input
Contactor

#4

Work Lead

OUTPUT

DIODE

PCB

#8

#9

To Main Trans­former (Secondary)

#43

#33

Torch
Switch

To Output
Inductor

#32

To Bulk­head

To CD
Transformer

To PCR
Relay

NOTE

Boards for use with 19x1751 (3.5" x 4") CD PCB include R85.
Do not install shorting connector in J27.

Boards for use with 19x1729 (4" x 7") CD PCB omit R85. Install
shorting connector in J27.

Manual 0-2806 A-23 APPENDIX

APPENDIX 10-D: MAIN PC BOARD WIRING (for 400-Volt

and 460-Volt units)

To Input
Contactor

Input

Diode

Assembly No. 19x1743 AA

M1 Fan
Harness

Solenoid/Pressure
Switch Wire Harness

To Main
Transformer
(Primary)

Auxiliary

Transformer

T o Thermal Protection
Device on Output Inductor

T o Thermistor
on Heatsink

ON/OFF
RUN/SET
Wire Harness

to Pot/LED
PCB

Torch
Switch

A-03085

#1

#2

#44

To Input
Contactor

IGBT

Work Cable

Output
Diode

To Main Trans­former (Secondary)

#43

#33

To Output
Inductor

To Bulk­head

To CD
Trans­former

TO PCR
Relay

APPENDIX A-24 Manual 0-2806

APPENDIX 11: 28VAC CIRCUIT DIAGRAM

Line V oltage

SOL

1 2 5 6

0.5A Fuse

W1

J4

Auxiliary

Transformer

J81

primary

J8

4

J3

3 4 5 6

ON/OFF Switch

J5

2

3

1

secondary

K2

K5

A-02770

Manual 0-2806 A-25 APPENDIX

Main Power PC Board

Voltage
Protection
CRT/+12 Regulator

+12vdc

APPENDIX 12: MAINTENANCE SCHEDULE

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

NOTE

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

Daily Operational Checks or Every Six Cutting Hours:

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

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

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

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

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

Weekly or Every 30 Cutting Hours:

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

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

CAUTION

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

Six Months or Every 720 Cutting Hours:

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

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

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

APPENDIX A-26 Manual 0-2806

This page left blank.

Manual 0-2806 A-27 APPENDIX

APPENDIX 13-A: SYSTEM SCHEMATIC (208/230-Volt units

with Main PC Boards Rev. G or earlier)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

A-02943

APPENDIX A-28 Manual 0-2806

24 25 26 27 28 29 30 31 32 33 34 35 36
24 25 26 27 28 29 30 31 32 33 34 35 36

Manual 0-2806 A-29 APPENDIX

A-02943

APPENDIX 13-B: SYSTEM SCHEMATIC (208/230-Volt units

with Main PC Board Rev. H or I)

A-03031

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

APPENDIX A-30 Manual 0-2806

24 25 26 27 28 29 30 31 32 33 34 35 36
24 25 26 27 28 29 30 31 32 33 34 35 36

A-03031

Manual 0-2806 A-31 APPENDIX

APPENDIX 13-C: SYSTEM SCHEMATIC (208/230-Volt units

with Main PC Board Rev. J or later)

A-03269

APPENDIX A-32 Manual 0-2806

Manual 0-2806 A-33 APPENDIX

A-03269

APPENDIX 13-D: SYSTEM SCHEMATIC

(400-Volt and 460-Volt units)

A-02967

APPENDIX A-34 Manual 0-2806

Manual 0-2806 A-35 APPENDIX

A-02967