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151 CUTMASTER™ Service Manual

Contents

1. 1 2 3 4 5 L1 1 208 230V E12A 1PHASE E17A INPUT 12 WT d DRIVE 1 2 L3 wi E9A A 3 E11A A P7A wi a 78 E19A i INPUT DIODE E21A P IGBT BOARD 21 55 19 1787 I COPPER STRAP E12B E17B GND 4 6 P11 B R30 0 ohm M1 Fi E19B FAN1 6 10A soo E21B IGBT BOARD ASSY 19X1787 28VACB 28VAC A M2 FAN2 P31 28VAC B 21 28VAC A 214 24 8 TO BIAS SUPPLY P30 SW 125 6 52 17 swi 8 RUN i P25 MODE SW as SET 2 RAR OFF lt 9 PILOT PCB F9 sw2 CURRENT ADJUST E5 TS2 5 100 AMP 151 J14 14 P27 J27
2. 1 2 3 4 5 E6 Li Wl EB E12A GATE E5 DRIVE J3A P3A E13 600VAC L2 1 3PHASE QO 2 E18 INPUT 11A E14 7A 13 wi E16 E19A INPUT DIODE E21A IGBT BOARD ASSY 19X1787 x E12B GATE FILTERING E17B DRIVE J3B P3B 4 6 9B B 11B 0 ohm 1 5 19 E 3 10A 600V 21 7 1 i Ka IGBT BOARD 6 ASSY 19X1787 57 2 28VAC B ZEVAC A t ON OFF SW e T To BIAS SUPPLY P30 we 26 2 RUN i P25 MODE SW 1 RAR lt 48 PILOT PCB F9 sw2 H gt E5 152 E6 T51 27 27 5 1 2 2 57 2 2 WIPER CURRENT 515 5 5 CONTROL 5 5 By 59985 em MAIN TRANSFORMER LED PCB 427 bc 19 1604 CURRENT SENSE IGBT HEATSINK TEMP INDUCTOR TEMP 133 P33 P39 OUT 5 1 um ili 2 2 77 242 TIP SENSE 3 173 313 e HE
3. e es i nr 1 e TORCH WORK M Art 04645 F F Heatsink Shroud Assembly Removal The Heatsink Shroud Assembly must be disengaged for access to either the Main Transformer or the Output Inductor Follow these steps for access to either component 1 2 3 Remove the power supply cover per Section 5 02 Release the tab on the vertical face of the Heatsink Shroud securing theSolenoid Pressure Switch Assembly in position Remove the gas hose from the Regulator Fitting on the back panel of the Power Supply by pressing on the locking ring on the elbow fitting while pulling on the hose Remove the Power Supply Back Panel per subsection 5 05 D Remove the grommets from the two holes on the right rear edge of the Heatsink Shroud Remove the Fan Assembly per subsection 5 06 A Label and disconnect the wires connected to the Pilot PC Board Remove the hardware securing the Pilot PC Board in place Pull the PC Board off the center chassis Label and disconnect wires No 45 47 49
4. 6 7 8 9 10 COMP DESCRIPTION LOCATION FUSE 3 10A 600V FNQ R FUSE 0 9A RESETABLE OUTPUT INDUCTOR FAN 4 5 220 FAN 4 5 220VAC PRESSURE SWITCH GAS SOLENOID A SWITCH ON OFF SWITCH RUN SET RAR MAIN TRANSFORMER TEMP SENSOR IGBT HEATSINK TEMP SENSOR INDUCTOR MAIN CONTACTOR NOTES UNLESS OTHERWISE SPECIFIED 1 DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS IS FOR REFERENCE ONLY OPTIONAL AUTOMATION INTERFACE CONNECTIONS B PLUGS INTO J27 ON MAIN BOARD ALTERNATE 20 PIN HEADER l 20 POSITION TERMINAL STRIP LED PCB 19X1604 1 1 114 P3 i 48 313 149 2 HE Hn 5 TORCH SWITCH Gee 6 6 19 2041 818 OPTIONAL AUTOMATION OK TO MOVE INTERFACE UT P 1 DIVIDED OUTPUT ADAPTER HARNESS USED mu 0 WHEN REMOTE CURRENT T 51 8 CONTROL IS USED WITH 81 2 2 3 1 REMOTE CURRENT CONTROL REPLACES CONNECTIONS 152 5 1 FROMJ27TO 14 DST 5 DC COMMON 1 eis Ns __ m NEG 7 2 8 1 1 i HOUSING e 4 Ft switcH PE T m 5 MOVE T E sen T 8 m LOGIC COMMON OUTPUT INDUCTOR 641 n VOLTS C amp G U 1 l
5. J25 PCB ASSEMBL 19X2197 19X2190 2 230v E10 me 60 6 E20 J30 J31 Art A 04640 Main Power PC Board Signals J11 1 Jli4 L3Input 15 1 1 J15 2 2 53 Notused 54 Notused J15 5 Fan MI1 5 6 Fan M2 718 1 Notused 182 Notused 18 5 28VACB 18 4 28VACA 185 On OffSwitch J18 6 On OffSwitch J18 7 Run SetSwitch J18 8 Run SetSwitch APPENDIX 23 1 23 2 23 3 242 J243 paa 5 J246 47 24 8 1254 ps 4 Test Test Gas Solenoid SOL1 Gas Solenoid SOL1 Pressure Switch PS1 Pressure Switch PS1 Main Contactor W1 Main Contactor W1 Not used Not used Gate Drive Gate Drive Manual 0 4669 7264 262 74 72 73 27 4 27 5 27 6 77 27 8 29 1 29 2 29 3 29 4 J30 1 J30 2 J31 1 J31 2 732 1 J32 2 J33 1 J33 2 J33 3 J33 4 J33 5 J33 6 J33 7 J33 8 Gate Drive Gate Drive PotHigh Pot Wiper Pot Low Dv AC Gas Overtemp Heatsink Temp 151 Heatsink Temp 151 Jumper Jumper Gate Drive Gate Drive Gate Drive Gate Drive Inductor Temp Switch TS2 Inductor Temp Switch TS2 Out Sense DCCom Tip Sense 12 CSR ISense Notused Tip volts PIP Return PIP
6. H J27 al EET is 27 2 22 EL Input Diode E30 mounts to center chassis E15 J25 1 0 19 2198 T 19X2199 60 V 20 1 J30 E4 J31 E23 E12 Art A 04640 Main Printed Circuit Board Layout logicboard notshown TROUBLESHOOTING 4 14 Manual 0 4669 SECTION 5 SERVICE 5 01 General Maintenance A Filter Element Replacement The Regulator Filter Assembly is on the rear panel For better system performance the Regulator Assembly filter element should be checked regularly and either cleaned or replaced 1 6 7 Remove power from the power supply turn off the gas supply and bleed down the system Turn the regulator adjustment knob to the zero setting 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 Grasp the filter element and unscrew it from the Regulator Filter body The filter element will come off with a spool a
7. 2 APPENDIX 3 LOGIC PC BOARD LAYOUT A3 APPENDIX 4 MAIN POWER PC BOARD LAYOUT A4 APPENDIX 5 MAIN PC BOARD WIRING LAYOUT 208 230 Volt Units VU 6 APPENDIX 5B MAIN PC BOARD WIRING LAYOUT 400 Volt 460 Volt and 600 Volt Units 7 APPENDIX 6 LED POT PC BOARD LAYOUT A8 APPENDIX 7 IGBT CIRCUIT PG BOARD LAYOUT uiae ettet rt etc ren dde 9 APPENDIX 8 OUTPUT DIODE PC BOARD LAYOUT nennen tenni A 10 APPENDIX 9 OUTPUT BOARD WIRING DIAGRAM 11 APPENDIX 10 PILOT PG BOARD LAYOUT tbe terree tpe ib A 12 APPENDIX 11 28VAC CIRCUIT A 13 APPENDIX 12 DATA TAG INFORMATION inner A 14 APPENDIX 13 TORCH PIN OUT DIAGRAMS A 15 APPENDIX 14 TORCH CONNECTION DIAGRAMS inner 16 APPENDIX 15A SYSTEM SCHEMATIC 208 230 Volt Units A 18 APPENDIX 15B SYSTEM SCHEMATIC 400 460 Volt Units VV A 20 APPENDIX 15C SYSTEM SCHEMATIC 600 Volt Units A 22 APPENDIX 16 Publication rer e arent ere ere A 24 Global Customer Service Contact Information 2 2 0 Inside Rear Cover SECTION 1 GENERAL INFORMATION 1
8. E Noarcor intermittent arc in torch Gas flows AC _ GAS and DC indicators ON TEMP indicator off Art A 03992 0 5 6 x 7 1 Gaspressure set incorrectly too high a Reset gas pressure per pressure setting label on power supply 2 Oil moisture in air lines a Put the ON OFF switch in the ON up posi tion Putthe RUN RAPID AUTO RESTART SET switch in the SET down position Manual 0 4669 b Place a welding filter lens in front of the torch and turn on the air Any oil or moisture in the air will be visible on the lens Do not start an arc c Purge system If problem corrected add filters in line with air source 3 Incorrect torch parts a Inspectthe torch parts replace as needed 4 Faulty leads a Checktorch leads continuity 5 Faulty torch a Check torch 6 Faulty connection of wire 58 or 62 to Pilot Board a Check wiring connection Refer to the System Schematic in the Appendix Connections should be e Wire 58 to Pilot Board terminal E58 e Wire 62 to Pilot Board terminal E62 If wires 58 and 62 are not connected to the proper terminals replace the Pilot Board 7 Faulty Main PC Board a Check for approximately 12 vdc at TP4 to TP1 If less than 2 vdc replace the Main PC Board 8 Faulty Logic Board or Faulty Pilot Board a Install a jumper between wires 58 and 62 on
9. 1 2 3 4 5 wi L1 12 x GATE N ac E17A DRIVE O 7 208 230V 400 415V w1 ale 1PHASE 460V 2 2 INPUT 3 PHASE D ESA A INPUT DAVE Fg wi J7A P7A 3 nr INPUT DIODE ale 11 p IGBT BOARD E33 El E2 E3 400V 1 22 PHASE 22 7 GATE CHASSIS FILTERING DRIVE J3B GND m e 400V CE VERSION HHR Fe Ki INCLUDES IN LINE 5 Fi 3 B EMC FILTER R29 415 460 600V m R78 400V 4 a Bron Ti 04 FAN1 E20 P15 230V lo 7 21 L 5 33 IGBT BOARD 6 Li 515 28VACB 28 8 T E30 230V sys SEE TABLE 1 FOR oc M2 F1 R29 R30 amp R78 FAN2 J26 iTi P26 Pig J18 28 J31 1 P31 28VAC 21 2 3 als 2BVAC 122 HE M sw 1 HE TO BIAS SUPPLY oo ca 2 2 Swi 818 MODE SW RUN avoc 425 m P25 SW us 8 PSET 22 RAR OFF lt PILOT PCB Z INRUSH F9 SW2 CURRENT ADJUST ES 152 5 100 AMP FAN E6 51 J14 P14 P27 J27 j Por HIGH ER 140 GAS MAIN TRANSFORMER 6 6 6 6 GAS LED PCB 8 8 E 8 8 8 E32 T5 GAS o d o D 2 CURRENT SENSE z 5 7 P29 J29 IGBT HEATSINK e TEMP 44 LE t TS1 P32 432 o z 4 52 E47
10. 19X2198 400V m 19X2199 5009 Art 04648 Reconnect all wiring Refer to Appendix pages in this manual for wiring details SERVICE 5 16 Manual 0 4669 F Input Power Cable Replacement 1 2 4 FO F Main Input Contactor 400 460 600Volt Remove the power supply cover per Section 5 02 A Locate and label the input power cable connections and disconnect the cable Connections to Main PCB Main Contactor Art A 03194 Art A 03212 Main Input Contactor 208 230Volt Unthread the retaining nut on the Input Cable Strain Relief on the inside of the Rear Panel and remove the Input Power Cable from the unit Install the replacement Input Power Cable by reversing the above steps The Input Power Cable ground wire requires a ring terminal EMI Filter Replacement CE Units Only Remove the power supply cover per Section 5 02 Label the input power cable connections and the cable connections to the main input contactor Disconnect all wire and cable connections to the EMI Filter Remove the hardware securing the EMI Filter This hardware passes upward through the base of the power supply Putthe replacement EMI Filter in position and secure it with the hardware removed in Step 4 Connect the input power cables and the cable connections to the main input contactor Test the Power Supply for proper operation Manual 0 46
11. Por HIGH E10 25742 2 WIPER CURRENT JE POTEOW E27 CONTROL 5 40 5 MAIN TRANSFORMER LED PCB 6 0276 19 1604 142 E32 D CURRENT SENSE P29 IGBT 5 HEATSINK 8 TEMP SEN 2 rs P32 1 2 INDUCTOR J33 P33 P39 OUT 1 11 1 DC COM 2 2 72 2 TIP SENSE 3 3 55 3 12VDC 4 4 73 4 CSR 5 09 5 ISENSE 6 6 8 TIP voLrs 8 8 72 8 COM ATC CONNECTION SENSE CONFIGURATION 2 CONTACTOR ON J34 P34 STANDARD TL iv on ors PIP RTN 2 2 79 22 PIP a K4 DRAG ON 4 D25 DCOK TORCH SW 4 4 177 OVIEME SOLENOID ON TORCH SW ENT TORCH SW ON Goss AC OK sw TORCH SW AINA SA 777 NS SONEGTOR POT HIGH J23 ATC RECEIVER POT WIPER POTLOW 28VAC A gale TEST GATE DRIVE A RTN 28VAC B CONN GATE Acron INSTALLED OPTIONAL CURRENT SENSE SOL1 ITORCH MOUNTED GAS SOLENOID CURRENT SENSE E A se te CURRENT SENSE RIN RESETABLE 1 8 5 URRENT SENSE o DC PU Hamoa SOLENOID F 5 PRESS GOOD ET ISENSE B 5 Hg PRESSURE Logic Tie ocre MAIN BOARD 51 A CLOSED WHEN ASSY 19X2189 PRESSURE OK EXTENDER ASSY 19X2286 ASSY 19X1775 ASSY 19X2190 I MAIN CONTACTOR WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED SOL1 IS POWERED BY T6 ONI LY 5012 POWERED BY 24 1 2 Art A 07156
12. 100 Particulates to 20 Microns Cure 100A 73A Devora 120v tov 19V NOTE The duty cycle will be reduced if the primary input power AC is low or the output voltage DC is higher than shown in this chart NOTE IEC Rating is determined as specified by the International Electro Technical Commission These specifications in clude calculating an output voltage based upon power supply rated current To facilitate comparison between power supplies all manufacturers use this output voltage to determine duty cycle TDC Rating is determined using an output voltage representative of actual output voltage during cutting with a TDC torch This voltage may be more or less than IEC voltage depending upon choice of torch consumables and actual cutting operation Manual 0 4669 3 1 DESCRIPTION Handle and Leads Wrap Control Panel Art A 04507 Work Cable and Clamp Gas Pressure Regulator Filter Assembly Gas Inlet Port Ports for Optional Automation Interface Cable f Art A 03738 Input Power Cord DESCRIPTION 3 2 Manual 0 4669 3 Dimensions and Weight 83 Ib 37 6 kg 17 3 in 439 mm PE 12 4 in A 03572 315 mm 1 Front Panel Controls and Features Main Power ON OFF Switch RAPIDAUTORESTART SET a Switch Output Current Control A Sets output current for dra
13. To Logic Board via Connector To Main Transformer MAIN PCB ASSEMBLY 19X2197 460V 19X2190 208 230V 19 2198 400 192199 Art A 04567 Heat Sink To Input 10 m Temp Sensor Contactor eee If installed in conjuction with Automation Interface Board is not installed in all units Automation Interface PC Board APPENDIX A 6 Manual 0 4669 APPENDIX 5B MAIN PC BOARD WIRING LAYOUT 400 Volt 460 Volt and 600 Volt Units To Inductor Temp Sensor To Power Output Board To Press Switch Solenoid Contactor LT1 Test To Heat Sink To On Off and o Chassis Connector Run Rapid Restart Ground Fuse To Main 3E To Torch Set Switches Input Contactor dela Connector es p No mes 10 Auto Interface 2009 Meese 2 Boar
14. Description Ref Fuse F1 for 208 230 Volt Power Supplies for 400 Volt Power Supplies for 460 Volt Power Supplies for 600 Volt Power Supplies Main Input Contactor for 208 230 Volt Power Supplies for 400 Volt 460 Volt and 600 Volt Power Supplies Connector PCB for RoHS PCB Assembly Logic Board for non mechanized units for RoHS PCB Assembly Logic Board for Mechanized units PCB Assembly Kit IGBT Circuit 208 230V 400V and 460V Units IGBT Diode IGBT PCB Thermal Pad for RoHS PCB Assembly Kit IGBT Circuit 600V Units IGBT Diode IGBT PCB Thermal Pad Input Diode PCB Assembly Main Power for 208 230 Volt Power Supplies for 400 Volt Power Supplies for RoHS for 460 Volt Power Supplies for 600 Volt Power Supplies EMI Filter Kit CE Power Supply Only NOTE Illustration may vary slightly from unit PARTS LISTS Catalog 9 8588 9 8602 9 8583 9 8638 9 8587 9 8554 9 8576 9 0051 9 8338 9 0071 9 9442 9 8334 9 0053 9 8666 9 8030 9 8340 9 8342 9 0075 9 8341 9 8343 9 8664 Manual 0 4669 Art A 04514 PARTS LISTS 6 5 Manual 0 4669 6 06 Rear Panel Replacement Parts Item Qty 1 1 2 1 3 1 4 1 1 1 1 1 5 1 6 1 Description Ref Assembly Filter Regulator Regulator Filter Replacement Element Regulator Mounting Bracket Input Power Cable for 208 230 Volt Units Non CSA for 208 230 Volt Units CSA for 460 Volt and 600 Volt Three Pha
15. 19X2041 18 1 GAS OPTIONAL 6 amp AUTOMATION 5 OK TO MOVE INTERFACE 3 3 PNE 2 1 DIVIDED OUTPUT ADAPTER HARNESS USED P1 0 WHEN REMOTE CURRENT H WITH 89 COMMON 1 REMOTE CURRENT CONTROL 24 REPLACES CONNECTIONS ew 5 5 FROM J27 TO J14 51245 HOBEHSW 4 4 DC COMMON nec 7 7 3 8 8 2 HOUSING 1 cT 1 TORCH SWITCH a 5 ok ro on 8 FE sen a 8 LOGIC COMMON 1627 3 my ARC VOLTS C amp G OUTPUT INDUCTOR Li i ST ee Ee E Y ene T L1 D RECEIVER ATC MALE CONNECTOR E64 E64 E35 E62 CSR T E49 E45 E35 E61 E3 E1 62 E43 E32 O R PILOT E64 058 E37 CURRENT SENSE A E58 JUMPER E58 WORK E E34A C1 MODE SW RAR OFF 52 51 J40 P40 12VDC 1 1 2 2 OUTPUT DIODE OUTPUT DIODE i 3 46 ASSEMBLY 19X2213 ASSEMBLY 19X2213 658 515 17 77 18 E34A ISENSE 8 8 E50B N28 PILOT BOARD E39 ASSY 19X2157 CHASSIS E63 THRU SCREW TERMINAL 5 56 oND Rer Reve Nor F 54 101593 REL HAS 032105 IHERMAL DYNAMICS TASMAN PAM ECO B028 RS 2 27 05 A MEST LEBANON NHO3784 Scale supersedes ACTECO 8016 RWH 01 27 06 A THERMADYNE Company cs OUTPUT DIO
16. Replace the Heatsink Shroud per paragraph SERVICE 5 24 Manual 0 4669 1 9 Heatsink Shroud Assembly Replacement Pass transformer wires 45 and 49 through the upper hole in the right rear edge of the Heatsink Shroud Pass trans former wires 47 and 52 through the lower hole Route wires as follows a Passthered wires from the output inductor through the upper hole in the right rear edge of the Heatsink Shroud b Pass the black wires from the output inductor through the lower hole in the right rear edge of the Heatsink Shroud Refer to Appendix 9 Power Output Board Diagram c Pass the wires from the temperature switch on the Output Inductor through the upper hole in the Shroud Re install the Heatsink Shroud as follows a Liftthe Heatsink Shroud Assembly into position Studs on the Power Supply base pass through holes in the bottom flange of the Shroud b Swing the top edge of the Shroud Assembly into place Studs on the Center Chassis of the Power Supply pass through holes in the top flanges of the Shroud c Ensure thatthe rubber feet on the Main Transformer engage holes in the Shroud d Puthex nuts on the studs Tighten the nuts on the right rear top and bottom studs Leave the nuts on the left forward studs loose temporarily Putthe Fan Assembly in place per subsection 5 06 A Reconnect the work cable to terminal E61 on the Power Output PC Board Tighten the nuts securing the left edge of the Heat
17. ET LA SANT LORS DES OP RATIONS DE COUPE ET DE SOUDAGE L ARC ET AU GAZ disponible aupr s du Superin tendent of Documents U S Government Printing Office Washington D C 20402 4 Norme ANSI Z87 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRA VAIL ET DANS LES ECOLES disponible de l Institut Am ricain des Normes Nationales American Na tional Standards Institute 1430 Broadway New York NY 10018 5 Norme ANSI 741 1 NORMES POUR LES CHAUSSURES PROTECTRICES disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 6 Norme ANSI Z49 2 PR VENTION DES INCENDIES LORS DE L EMPLOI DE PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de l American Na tional Standards Institute 1430 Broadway New York NY 10018 7 Norme A6 0 l Association Am ricaine du Soudage AWS LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERM DES PRODUITS COMBUSTIBLES disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Am ricaine pour la Pro tection contre les Incendies NFPA LES SYST MES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCI S disponible aupr s de la Na tional Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 GENERAL INFORMATION 10 11 12 13 14 15 Norme 70 de la NFPA CODE ELECTRIQUE NA TIONAL disponible a
18. TAINERS WHICH HAVE HELD COMBUSTIBLES ob tainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PRO CESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Associa tion Batterymarch Park Quincy MA 02269 NFPA Standard 51B CUTTING AND WELDING PRO CESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 CGA Pamphlet P 1 SAFE HANDLING OF COM PRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 CSA Standard W117 2 CODE FOR SAFETY IN WELD ING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Associa tion 1900 Arch Street Philadelphia PA 19103 American Welding Society Standard AWSF4 1 RECOM MENDED SAFE PRACTICES FOR THE PREPARA TION FOR WELDING AND CUTTING OF CONTAIN ERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 ANSI Standard Z88 2 PRACTICE FOR RESPIRATORY PROTECTION obtainable from American Natio
19. To Pilot To Main To Pilot PCB B Output Chassis Ground E37 E35 E62 E47 J39 x E36 Diodes YS T ES Mu E le iw PILDT os ees VES ed x x E32 A Output 191914 Diodes P 5 To Output 5 Inductor To Pilot E45 ES To Trans E64 former E49 To Torch 2 1 c E64 E43 Y re 6 E To Trans m 2 al me i former TORCH e Ce WORK M E43 Output E58 E52 WorkCable E61 E57 Inductor E29 Raw Arc Voltage Connections Manual 0 4669 11 APPENDIX APPENDIX 10 PILOT PC BOARD LAYOUT Connector J28 R9 gos y 1185 1 Connector J1 E58 E62 PILOT BOARD 19X2157 REV Art A 04582 Connector E58 Connector E62 Pilot PC Board Signals 181 412vdc J28 2 DCCom 183 Mode Switch R
20. cations Section 3 Input Line Voltage is low a Check and connect to proper input power line TROUBLESHOOTING 4 12 4 Faulty Temperature Sensor Switch m A _ Turn off input power for the following tests a Check IGBT Heatsink Temp Sensor 151 Dis connect wire connector P29 from terminal J29 on Main PC Board Check connector pins 1 and 2 for 10k ohm 25 at ambient temperature If resistance is not 10K ohm 25 replace TS1 Check Inductor Temp Switch TS2 Disconnect wire connector P32 from terminal Jew on Main PC Board Check connector pins 1 and 2 for at least 12K ohms If resistance is less than 12K ohms replace output inductor L1 If temp switch is open replace Main PC Board 5 Faulty Logic PC Board a Check for 12 vdc on Logic PC Board between J43 9 and TP1 If 0 vdc is present replace Logic PC Board 6 Faulty Main PC Board a Check for 0 vdc on Main PC Board between J43 9 and TP1 If 0 vdc is present replace Main PC Board 7 Faulty Fan s Measure for 230VAC on Main PC Board from J15 1 to J15 5 and from J15 2 to J15 6 If voltage at 15 1 to 15 5 is correct replace upper fan M1 Ifvoltage at 15 2 to J15 6 is correct replace lower fan M2 Manual 0 4669 D Gas flows AC indicator and GAS indicators ON TEMP indicator off DC indicator off or blinks on off once Art A 03991 A EN
21. 1 DC COM 2 2 351 OUTPUT DIODE OUTPUT DIODE 22 49 ASSEMBLY 19 2213 ASSEMBLY 19 2213 258 5 5 7 5 18 ISENSE 8 g 5 B 28 PILOT BOARD CHASSIS GND E63 THRU SCREW TERMINAL Rer Revisions ose ECO 101593 REL 032105 IMERMAL Dynamcs pot 101714 HAS 05 23 05 OUTPUT DIODE OUTPUT DIODE 101726 HAS 06 10 05 THERMADYNE Company Momms DG COMMON 7 Aomv idees COMMONS Fae ol mee ry POWER OUTPUT BOARD ASSY 8270 01 05 07 NOTE otherwise Resistors in Ohms 1 4W 5 Capactors are in Miroferads UF TITLE SCHEMATIC Las Moaea Fray January 05 2007 110525 151 400 415 460V SYSTEM D 42X1188 6 7 8 9 10 Art A 07641 Manual 0 4669 A 21 APPENDIX APPENDIX 15C SYSTEM SCHEMATIC 600 Volt Units
22. Art A 02847 C Cover Installation 1 Reconnect the ground wire if necessary Place the cover onto the power supply so that slots in the bottom edges of the cover engage the lower screws Tighten lower screws N Reinstall and tighten the upper screws SERVICE 5 6 Manual 0 4669 5 03 Front Panel Parts Replacement A Disconnect input power at the source and bleed down the system before attempting these procedures A Current A Control Knob Replacement Turn the control knob fully clockwise and note the location of the pointer on the knob Loosen the screw securing the Knob to the potentiometer shaft and remove the Knob Place the replacement Knob on the potentiometer shaft with the location of the pointer the same as noted in step 1 Tighten the screw to secure the knob to the potentiometer shaft B ON OFF Switch SW1 Replacement 1 Remove the power supply cover per Section 5 02 A 2 Disconnect the wires on the rear of the ON OFF Switch Note the location of each wire as shown below Top clip Wire 21 lt lt M Wire 22 Wire 24 Wire 23 Art A 02774 3 Squeeze together the clips on the top and bottom of the Switch Remove the Switch through the Front Panel 4 Install the replacement Switch by reversing the above steps 5 Reinstall the power supply cover Manual 0 4669 5 7 SERVICE C RUN RAPID AUTO RESTART SET Switch SW2 Replacement 1 Remove the power supp
23. Circuit Fault ISOlAtON 4 4 4 07 Main Input and Internal Power Problems eee 4 5 4 08 Pilot Arc Problems ai a bebes 4 11 4 09 Main Arc Problems iii 4 14 SECTION 5 5 1 5 01 General Maintenance iii 5 1 5 02 Power Supply Major External Parts Replacement 5 5 5 03 Front Panel Parts 5 7 5 04 Left Side Internal Parts Replacement 5 9 5 05 Rear Panel Parts 5 18 5 06 Right Side Internal Parts Replacement 5 20 TABLE OF CONTENTS continued SECTION 6 PARTS LISTS e EU 6 1 6 01 meet 6 1 6 02 Ordering Information su 6 1 6 03 Major External Replacement Parts 6 2 6 04 Front Panel Replacement 6 3 6 05 Left Side Internal Component Replacement Parts 6 4 6 06 Rear Panel Replacement Parts 6 6 6 07 Right Side Internal Component Replacement 6 7 6 08 Options and 6 8 PATENT INFORMATION dei eee 6 9 APPENDIX 1 INPUT WIRING REQUIREMENTS ire 1 APPENDIX 2 SEQUENCE OF OPERATION BLOCK DIAGRAM E
24. Notused Notused Torch Switch Return Torch Switch 12 vdc to Logic PCB Manual 0 4669 43 2 J43 3 J434 J43 5 J43 6 J43 7 J43 8 J43 9 A 5 12 vdc to Logic PCB Pressure Good Overtemp CSR Gason DCOK OVTEMP ACOK Torch Switch Torch Switch Return 12vdc POT High POT Wiper POT Low Gate Drive B Return Gate Drive B Gate Drive A Return Gate Drive A Out Sense Current Sense Current Sense Current Sense Return Current Sense Return Tip Volts Ground 12 APPENDIX APPENDIX 5A MAIN PC BOARD WIRING LAYOUT 208 230 Volt Units To Press Switch Solenoid Contactor To Inductor Temp Sensor To Power Output Board To Heat Sink Temp Sensor LT1 To Main Test Connector Input Contactor To On Off and Run Rapid Restart Set Switches To Torch Connector To Chassis Ground To Auto Interface FOR 208 230V cd TE EE ELEC es T Board J1 5 To Auto Interface ic gt Secondary nel C e Transformer To PCB Ig 72 or to rap s Optional Remote Current Control
25. RAPID AUTO RE START SET switch in RUN or RAPID AUTO RESTART AC and GAS indicators ON Temp JE and DC indicators OFF qq e 1 Gas pressure is below torch minimum requirement NOTE Minimum pressure for power supply opera tion is lower than minimum required for torch opera tion Art A 03990 gt 92 a Adjust gas pressure per pressure setting label on power supply 2 Torchtip starter cartridge or electrode missing a Turn off power supply Remove shield cup in stall missing parts TROUBLESHOOTING 3 Torch starter cartridge is stuck a Turnoff power supply Remove shield cup tip and starter cartridge Check lower end fitting on starter cartridge for free movement Replace cartridge if lower end fitting does not move freely Start Cartridge Lower End Fitting Art A 03621 4 Wornor faulty torch parts a Inspecttorch consumable parts Replace if nec essary C Torch will not pilot AC _ TEMP 3 and GAS indicators ON DC indicator off A 2 0 e 0 E Art A 03989 NP n 1 Air flow blocked a Check for blocked air flow around the unit and correct condition 2 Unit is overheated a Let unit cool down for at least 5 minutes Make sure the unit has not been operated beyond Duty Cycle limit Refer to duty cycle data in Specifi
26. and 52 from the Power Output PC Board Disconnect the wires from the Output Inductor to terminal E43 on the Power Output PC Board Disconnect the torch receptacle ground wire connected to the center chassis Manual 0 4669 5 23 SERVICE 10 Remove nuts on two studs at the top corners of the Heatsink Shroud and nuts on two studs on the bottom flange of the Heatsink Shroud 12 Remove the Heatsink Shroud as follows 1 2 7 a Usetheopenleftend of the Heatsink Shroud and the Pressure Switch Solenoid opening as handles b Pullthe Heatsink Shroud away from the center chassis and then up It may be necessary to pry the top and bottom flanges of the Heatsink Shroud slightly to release them from their mounting studs Movement will be limited by the wiring harness Main Transformer Removal and Replacement Disengage the Heatsink Shroud per Paragraph Disconnect wires 27 and 32 connected to terminals E27 and E32 on the Main Power PC Board Pull these wires through the hole in the center chassis Remove the transformer a Main Transformer slightly Swing its left edge away from the center chassis Pullits right edge away from the center chassis b Liftitoutofthe Power Supply through the opening at the rear of the Power Supply Position the replacement Main Transformer behind the Heatsink Shroud Assembly Position its wires at the right edge as you face it of the transformer Install the replacement transformer
27. es Epe L1 RECEIVER MALE CONNECTOR E64 E64 E35 E62 NEG T E49 E45 E35 E61 0 0 E62 E43 E32 R PILOT E64 TSR Vo H CURRENT SENSE AN 58 JUMPER EE E58 WORK E pe E48B MODE SW RAR OFF 52 538 1 BD E54B ee s 14 oc 2 2 05 OUTPUT DIODE OUTPUT DIODE i 3 ASSEMBLY 19X2213 ASSEMBLY 19X2213 5 5 17 HH 18 E348 ISENSE 818 E50A 50 28 PILOT BOARD E39 E398 ASSY 19X2157 CHASSIS GND cuis E63 THRU SCREW TERMINAL 5 53 E564 E56B Rev Revisions By Date gt nemus 54 E54B AA ECO 101593 2105 IHERMAL DYNAMICS INDUSTRALPARKNa2 ASSY No F EG0A E608 ST LEBANON cines Upersedes AB 8028 RS 12 27 05 eos pe ECO B016 RWH 01 27 06 THERMADYNE Company OUTFUT DIODE a E AD ECO B077 RWH 07 31 06 information Proprietary to THERMAL DYNAMICS CORPORATION 03 03 05 DC COMMON 7 DC COMMONS NotForReksse Repducion orDibuionwiboutWenConsen POWER OUTPUT BOARD ASSY 19X2191 NOTE Uniess Otherwise Specified Resistors are in Ohms 14W 5 HAS Capacitors are Microfarads UF Sheet TITLE SCHEMATIC Sze DWG No Try 27 206 110529 CM151 600V 3PH SYSTEM D 42X1189 6 7 8 9 10 Art A 07158 Manual 0 4669 A 23 APPENDIX APPENDIX 16 Publication
28. 01 Notes Cautions and Warnings Throughout this manual notes cautions and warnings are used to highlight important information These high lights are categorized as follows NOTE An operation procedure or background informa tion which requires additional emphasis or is help ful in efficient operation of the system me CAUTION A procedure which if not properly followed may cause damage to the equipment G A procedure which if not properly followed may cause injury to the operator or others in the oper ating area 1 02 Important Safety Precautions GS OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DAN GEROUS AND HAZARDOUS TO YOUR HEALTH Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers hearing aids or other electronic health equipment Per sons who work near plasma arc cutting applica tions should consult their medical health profes sional and the manufacturer of the health equipment to determine whether a hazard exists To prevent possible injury read understand and follow all warnings safety precautions and in structions before using the equipment Call 1 603 298 5711 or your local distributor if you have any questions Manual 0 4669 1 1 amp AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health K
29. 400 50 60 192 48 5 8 8 400 50 060 18 26 30 10 10 460 50 60 211 38 60 ____ 19 40 460 50 00 19 24 3 12 12 600 16 18 2 12 __ 12 Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electrical Code CE CutMaster 151 Input Wiring Specifications PowerInput Currentinput Suggested Sizes See Notes Voltage We te Fuse Amps Wire AWG Wire Canada Volts 1 Ph 3 Ph 1 Ph 3 Ph 1 Ph 3 Ph 400 50 192 48 50 T 40 50 18 26 30 45 50 192 48 5 8 J 8 qp 3b 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
30. Art A 04610 To Input To Input Contactor Contactor Input Diode Bridge Wiring 208 230V Units Input Diode Bridge Wiring 400 460 600V Units 11 Torque the screws securing the wires to the bridge to 22 in Ibs 2 5 Nm NOTE Failure to torque properly will cause component damage Manual 0 4669 5 13 SERVICE E IGBT Replacement Follow the antistatic instructions provided with the replacement partto prevent damage to the component 1 Notetheplacementofall wires to the IBGT s being replaced 2 Carefully remove the 3 sets of hardware securing each IGBT PC board being replaced to the IGBT module mounted to the power supply heatsink Keep the hardware for re use 3 Carefully remove the hardware securing the IGBT module s being replaced to the power supply heat sink Keep the hardware for re use 4 Useisopropylalcohol and a clean rag to clean the heat sink area behind the component being replaced Clean the large flat surface on the back of the replacement component Do not scratch or abrade the surface CAUTION The component mounting area and the mounting surface of the IGBT module must be free of debris pits scratches or other imperfections which could make the component lift off the mounting surface 5 Apply a thermal pad to the heatsink Secure in place with small pieces of masking tape to opposite corners The tape must cover no more than 1 4 6 mm of the edge of the thermal pad The threaded holes in the heatsink u
31. Corporation 1 Repair of the defective product 2 Replacement of the defective product 3 Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics 4 Payment of credit up to the purchase price less reasonable depreciation based on actual use These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon NH or an authorized Thermadyne service station Product returned for service is at the owner s expense and no reimbursement of travel or transportation is authorized LIMITATION OF LIABILITY Thermal Dynamics Corporation shall not under any circumstances be liable for special or consequential damages such as but not limited to damage or loss of purchased or replacement goods or claims of customer of distributors hereinafter Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of the goods covered by or furnished by Thermal Dynamics whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which liability is based This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performan
32. Input Contactor to the base of the power supply oO NY Position the replacement Input Contactor with the row of connectors labeled L toward the rear of the Power Supply Fasten in place with the hardware removed previously 7 Complete the wiring connections as shown NOTE It is important that wires are installed correctly as shown to prevent damage to the unit 8 Reinstall the power supply cover Connections to Main PCB dpa Contactor Art 03212 Main Contactor Art A 03194 400 460 600Volt Input Contactor 208 230 Volt Input Contactor 3 phase input power connections shown SERVICE 5 10 Manual 0 4669 C Logic PC Board Replacement Follow the antistatic instructions provided with the replacement part to prevent damage to the component The Logic PC Board connects to the Main PC Board through an extender board perpendicular to both boards 1 Remove the power supply cover per Section 5 02 A 2 Remove the bolts in each corner of the Logic PC Board 3 Detach the Logic PC Board and the extender board from the Main Power PC Board Detach the extender board from the Logic Board 4 Install the replacement Logic PC Board by reversing the above steps The pins on the right edge of the Logic PC Board must fully engage the sockets on the edge of the extender board The extender board must fully engage sockets on the Main Power PC Board D Input Diode Bridge Replacement Follow the a
33. MAIN CONTACTOR IS POWERED T6 ONLY SOL2 POWERED BY P24 1 2 Art 07641 1 2 3 4 5 2 APPENDIX A 20 Manual 0 4669 10 TABLE 1 COMP DESCRIPTION LOCATION Fi SEECHART 1 B2 460V 4007 aui 60 F2 09A RESETABLE F3 ZEROONN loc OUTPUT INDUCTOR D7 Mt FAN 4 5 220VAC B1 M2 FAN 4 5 220VAC ZERO OHM ZERO OHM 129 XXXXX pst PRESSURE SWITCH F4 Rap xxxxx xxxxx 5011 GAS SOLENOID F4 A SWITCH ON OFF A SW2 SWITCH RUN SET RAR 4 10 500 4 10 500 1 4A 500V Ts MAIN TRANSFORMER D4 TS1 TEMP SENSOR IGBT HEATSINK 01 TS2 TEMP SENSOR INDUCTOR Et W1 MAIN CONTACTOR F4 NOTES UNLESS OTHERWISE SPECIFIED 1 DEPICT
34. Pilot Board and retry piloting If torch pilots with jumper installed replace Pilot Board If torch does notpilot replace Logic Board 4 09 Main Arc Problems Locate your symptom below 4 13 TROUBLESHOOTING 4 09 Main Arc Problems Locate your symptom below A Main cutting arc will notstart 1 Work cable not connected a Connect work cable 2 Holding too high of a standoff a Refer to recommended standoff heights Adjust as needed 3 Workpiece is painted or rusty a Clean workpiece 4 Faulty Main PC Board or Logic Board a Measure for 0vdcatTP2 to TP1 on the Logic Board when attempting to transfer Refer to Logic Board Layout Ifvoltage goes to 0 vdc replace Output Board Ifnot replace Main PC Board 5 Faulty Main Input Contactor a Check per Subsection 4 10 D B When operating the amperage drops off after the main cutting arc starts 1 Torch tip contacts workpiece Lift the torch tip off the work At output settings over 40 amps circuitry in the power supply au tomatically reduces output current to 40 amps if the torch tip contacts the workpiece 2 Faulty Pilot Board a Withpower off and wires E58 and E62 disconnected from the pilot board measure for continuity between terminals E58 and E62 If continuity is found re place Pilot Board J33 J18 hi mm
35. Service Philosophy Several key points are essential to properly support the application and operation of this equipment A Application The equipment should satisfy the customer s requirements as supplied and as described in Section 3 of this manual Be sure to confirm that the equipment is capable of the application desired B Modifications No physical or electrical modifications other than selec tion of standard options and Accessories are to be made to this equipment C Customer Operator Responsibilities It is the customer operator s responsibility to maintain the equipment and peripheral accessories provided by Thermal Dynamics in good operating order in accordance with the procedures outlined in the operating manual and to protect the equipment from accidental or 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 sol der mounted components is allowed except as noted in this manual If PC boards are to be returned the replaced Printed Cir cuit Board Assemblies must be properly packaged in pro tective material and returned intact per normal procedures 2 03 Service Responsibilities The service technician should be familiar with the equip ment and its capabilities and should be prepared to rec ommend arrangements of components which will provide the most ef
36. as follows Pass the tabs on the right edge of the base of the transformer into slots in the center chassis of the Power Supply b Swing the transformer against the chassis and pass the tabs on the left edge of the base into slots in the chassis Press the transformer downward to lock it into position c Check for proper installation the transformer should remain securely in place Pass wires 27 and 32 through the hole in the center of the main chassis Connect wire 27 to terminal E27 and wire 32 to terminal E32 on the Main Power PC Board Reinstall the Heatsink Shroud Assembly per sub section I H Output Inductor Assembly Removal and Replacement 1 2 3 4 Disengage the Heatsink Shroud per paragraph Disconnect the wires to the thermal switch on the Output Inductor Remove hex nutsat the left forward and right rear corners of the Inductor base Remove the Inductor as follows a Note the position of the wires leading from the Inductor b Liftoutthe Inductor through the opening at the rear of Power Supply It may benecessary to liftthe Main Transformer slightly to create room for the Inductor to pass through the rear opening Install the replacement Inductor a Putthe replacement Inductor in place with the wires oriented the same way as the original Inductor b Secure the Inductor in place with hex nuts at opposite corners of the Inductor base Reconnect the wires to the thermal switch on the Output Inductor
37. in the bottom of the Fan Panel Ensure that the grommetis in place in the hole 11 Connect the Work Cable to terminal E61 on the Power Output PC Board Secure the Work Cable Strain Relief 12 Re install the Power Supply Cover B Work Cable Replacement I 2 Remove the cover per Section 5 02 A Disconnect the Work Cable from the E61 WORK terminal on the Power Output PC Board located on the right side of the unit Squeeze the top and bottom of the Work Cable Strain Relief and remove from the Front Panel Remove Work Cable from the unit Install the replacement Work Cable a Ensure that the replacement Work Cable passes through the grommet in the Fan Assembly Panel b Securethe Cable to the Work terminal on the Power Output PC Board and securing thestrain relief SERVICE 5 20 Manual 0 4669 C Pilot PC Board Replacement The Pilot PC Board mounts to the Power Supply center chassis Refer to Pilot Board Layout in the Appendix Follow the antistatic instructions provided with the replacement part to prevent damage to the component 1 2 4 6 Remove the power supply cover per Section 5 02 A Labeland disconnect wires from Pilot PC Board terminals E58 and E62 Disconnect the wire harness from receptacle J28 Remove the hardware securing the Pilot PC Board to the power supply center chassis Remove the Pilot PC Board Positionthe replacement Pilot PC Board against the standoffs fastened to the center chassis No
38. 0K 12 Faulty Main PC Board ohm 25 replace TS1 Measure for 12 vdc on Main PC Board from TP4 to b Shut input power off Check Inductor Temp TP1 Switch TS2 Disconnect wire connector P32 from terminal J32 on Main PC Board Check a If voltage is not present replace the Main PC connector pins 1 and 2 for resistance If resis Board tance is greater than 12K ohms replace output inductor L1 If temp switch is open replace D Fans do not run GAS and TEMP Main PC Board indicators ON DC indicator off E Nogas flow RUN RAPID AUTO RESTART SET switch in SET position AC indicator ON A TEMP GAS and DC indicators OFF e Q T 1 Air flow through unit is restricted 9 Art A 03984 00 NP m n Art A 03985 7 522 a Provide adequate air flow 2 Exceeded Duty Cycle of Power Supply 1 Gas supply not connected to unit a Deactivate torch and wait for fan to cool unit Refer a Connect to gas supply to Specifications Section for proper duty Cycle for this utt 2 Gas supply not turned on 3 Faulty Fan s a Turn gas supply on Measure for 230 VAC x on the Main PC Board 3 Gas pressure too low from J15 1 to J15 5 and from J15 2 to J15 6 a Adjust gas pressure per pressure setting label Ifvoltageat 15 1 to J15 5 is correct replace lower
39. 1 2 3 4 5 APPENDIX A 18 Manual 0 4669 6 7 8 9 10 COMP DESCRIPTION LOCATION FUSE 6 10A 600V KTK FUSE 0 9A RESETABLE OUTPUT INDUCTOR FAN 4 5 220VAC FAN 4 5 220VAC PRESSURE SWITCH GAS SOLENOID A SWITCH ON OFF SWITCH RUN SET RAR MAIN TRANSFORMER TEMP SENSOR IGBT HEATSINK TEMP SENSOR INDUCTOR MAIN CONTACTOR NOTES UNLESS OTHERWISE SPECIFIED DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS IS FOR REFERENCE ONLY OPTIONAL AUTOMATION INTERFACE CONNECTIONS B PLUGS INTO J27 ON MAIN BOARD ALTERNATE 20 PIN HEADER 20 POSITION TERMINAL STRIP P3 M 1 o Om on TORCH SWITCH
40. 412VDC 175 QE 7 E TIP VOLTS B ATC CONNECTION 818 CONFIGURATION PR CONTACTORON P34 n STANDARD am inv Gex 98 T SI agp PP 4 CASON 3 5 5 DRAG 8 025 ToRcHsWRTN 2 2 o SOLENOID ON TORCH SW 6 5 8013 3 eo SW 27033 SW 318 TORCHSWRINI m connector POT HIGH RECEIVER TEST AIR CONN SATE DRINE vy FACTORY INSTALLED OPTIONAL 00 TORCH MOUNTED GAS SOLENOID CURRE SOL1 2 gt K4 A B CURRENTS F2 0 9A P24 S bo RESETABLE 1 SOLENOID EXZ 2 me F PRESS GOOD 1 iH ENSE MAIN BOARD 2 013 Psi O PRESSURE E 1 T ASSY 19 2189 VOLTS ASSY 19X2190 8 SWITCH ASSY 19X2286 EXTENDER CLOSED WHEN assy 19X1775 JN PRESSURE OK MAIN CONTACTOR WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED 501115 POWERED BY T6 ONLY SOL2 POWERED BY P24 1 2 Art A 07158 1 2 3 4 5 APPENDIX A 22 Manual 0 4669
41. 669 APPENDIX 14 TORCH CONNECTION DIAGRAMS A Hand Torch Connection Diagram Torch SL60 SL100 Hand Torch Leads Torch Leads with ATC Connector Power Supply with ATC Receptacle Male ATC Leads ATC Female Connector Receptacle Power Leads To Power Supply Circuitry Torch To Power Supply Switch Circuitry 7 O1 D PO ODN Negative Plasma Negative Plasma Pilot Art 03797 B Machine Torch Connection Diagram Torch Unshielded Mechanized SL100 Machine Torch Leads Leads with ATC Connector and Power Supply with ATC Female Receptacle Male Gs ATC Female ATC Leads T UN Receptacle Connector ____ Power ____ Leads i Switch o Orange White Not To Power Supply Circuitry To Power Supply Circuitry BROOD Green Negative Plasma Lead Negative Plasma Pilot Lead Pilot Art A 03798 APPENDIX A 16 Manual 0 4669 This Page Left Blank Manual 0 4669 A 17 APPENDIX APPENDIX 15A SYSTEM SCHEMATIC 208 230 Volt Units
42. 69 5 17 SERVICE 5 05 Rear Panel Parts Replacement Disconnect primary power from the source before opening or disassembling power supply Filter Regulator Assembly Replacement Disconnect the gas supply at the source and bleed down the system before attempting this procedure Disconnect the gas input hose from the Filter Regulator Assembly on the Rear Panel of the unit Remove the four bolts securing the Regulator Mounting Bracket to the Rear Panel Disconnect the black gas tube from the Filter Regulator Assembly Adapter Fitting Hold a wrench or similar tool against the locking ring on the Fitting and pull on the tube to release it Removethenutsecuring the Filter Regulator Assembly to the Regulator Mounting Bracket Removethe Filter Regulator Assembly from the Mounting Bracket Install the replacement Filter Regulator Assembly by reversing the steps above When connecting the gas tube to the Adapter Fitting simply insert the hose into the fitting until fully seated and it will automatically lock B Filter Regulator Bracket Replacement 1 2 3 Remove the four bolts securing the Regulator Bracket to the Rear Panel Remove the nut securing the Filter Regulator Assembly to the Regulator Bracket Remove the Bracket from the Filter Regulator Assembly Install the replacement Bracket by reversing the above steps C Input Power Cable Replacement 1 2 3 Remove the cover per su
43. AR Off J28 4 NotUsed J28 5 Logic Low CSR J28 6 NotUsed J28 7 NotUsed 28 8 ISense E58 ToPowerOutput PC Board Terminal E57 E62 To Power Output PC Board Terminal E61 APPENDIX A 12 Manual 0 4669 APPENDIX 11 28VAC CIRCUIT DIAGRAM Line Voltage Auxiliary Transformer Voltage Protection CRT 12 Regulator A 03710 Main Power PC Board Manual 0 4669 A 13 APPENDIX APPENDIX 12 DATA TAG INFORMATION IHERMAL DYNAMICS West Lebanon NH USA 03784 Manufacturer s Name and or Company Logo Location Model and Model S N Revision Level Serial Number Date of Mfr Made in USA and Production Code Type of Power Regulatory Standard Covering Supply Note 1 135 5 This Type of Power Supply Output ir iin Type Duty Cycle Factor Output Range Amperage ZO 7 Voltage Plasma Cutting Symbol Ts x Uo Duty Cycle Data Note 3 U2 Rated No P Conventional Load Voltage Load Voltage Rated Maximum Supply Current Input Power Symbol Ui id 1 ag 12 Effective jx Supply Current Input Power Specifications Phase AC or DC Hertz Rating Manufacturer s Electrical Schematic File Number and Revision Level Degree of Protection Rated Supply Voltage Note 2 NOTES 1 Symbol shown indicates single or three phase AC i
44. B If0vdcis present replace Logic PCB Gas flows continuously when power is turned on AC indicator flashes TEMP indicator off GAS indicator ON DC indicator off Art A 03987 Cc 1 Torchswitch is activated closed before user turns power on a Release torch switch turn power supply OFF then ON with torch switch released 2 Faulty torch switch a Turn power supply Disconnect torch from power supply Refer to Appendix Pages for Torch Pin Out Diagrams Check torch switch continuity through sockets 3 and 4 NOTE In mechanized machine torch applications remote pendant control switch must also be closed Manual 0 4669 I 4 9 Gas cycles on and off when power is turned on AC indicator flashes TEMP indicator off GAS indicator 8 7 Art A 03987 1 Torch shield cup is loose a Tightenshield cup by hand Do notovertighten 2 Torch tip electrode or starter cartridge missing a Turn off power supply Remove shield cup in stall missing parts 3 Torch starter cartridge is stuck a Turnoff power supply Bleed down the system Remove shield cup tip and starter cartridge Check starter cartridge lower end fitting for free movement Replace cartridge if lower end fit ting does not move freely Start Cartridge Lower End Fitting 4 Sho
45. DE OUTPUT DIODE Information Proprietary to THERMAL DYNAMICS CORPORATION ASSEMBLY 19 2213 DC COMMON X7 ASSEMBLY 19X2213 DC COMMON YY fies POWER OUTPUT BOARD ASSY 19X2191 NOTE Unless Otherwise Specified Resistors are in Ohms 1 4W 5 HAS Capacitors are in Microfarads UF Chic em at THLE SCHEMATIC Sus Fart Hd Friday nva ET 2008 CM151 208 230V SYSTEM 42X1176 6 7 8 9 10 Art A 07156 Manual 0 4669 A 19 APPENDIX APPENDIX 15B SYSTEM SCHEMATIC 400 460 Volt Units
46. History Date Rev Comments 3 25 05 Placed on line no official release done 6 6 05 Revised added 400V 460V CE units updated 208 230V replacement rear panel amp cord cat no added 600V IGBT 6 27 05 Corrected Input Wiring Specs 7 8 05 Added 230V CSA rear panel and power cords parts per ECO 101731 10 12 05 Changed input wiring chart to Show Non CSA and CSA with some new cable ratings 2 3 06 Updated all art showing IGBT wiring by changing the bottom pair of red and black wires to show the black attached to the upper connection point 4 28 06 AA c pdated schematics per ECO B016 Updated torque specs on replacement parts per CO 101948 Added publication history Started using new cover styles 1 5 07 AB 01 Updated parts list and 400V schematic with RoHS information per ECOB270 3 14 07 AC 01 Updated 600 volt schematic to show new fuse 4 13 07 Updated C amp Cr section revised Troubleshooting Section pg 4 13 D deleted text 1a amp 2a references to Subsections 4 10 C amp 4 10 F updated Inside and Rear cover APPENDIX A 24 Manual 0 4669 IHERMAL DYNAMICS GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Email sales thermalarc com Thermadyne Canada 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 The
47. IHERMAL DYNAMICS 191 CUTMASTER PLASMA CUTTING SYSTEM Service Manual Rev AD 01 Date April 13 2007 Manual 0 4669 208 EEL Read and understand this entire Manual and your employer s safety practices before installing operat ing or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judgement the Manufacturer assumes no liability for its use Plasma Cutting Power Supply CutMaster 151 Operating Manual Number 0 4669 Covered under U S Patents Published by Thermal Dynamics Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermal dynamics com Copyright 2005 2006 2007 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Printed in the United States of America Publication Date April 13 2007 Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial Torch Serial TABLE OF CONTENTS SECTION 1 GENERAL INFORMATION 1 1 1 01 Notes Cautions and War
48. INDUCTOR 5 433 P33 P39 239 OUT sese 1 7108 TS2 DC COM 2 2 72 2 2 I ms ili Pi s43 24 t2voc 1 1 1 4 ISENSERS 818 MOMIE AE TIP VoLTS 8 8 77 als DC COM 4 4 414 Bd HE HB 6 CONFIGURATION RUNSET 717 ale CONTACTOR ON J34 STANDARD g E RIN 1 1 am 7 Di 998 5129 RE ere os a GASON 11 11 11 0 07 DRAG 025 2 12 12 12 TORCH SW RTN LER T 95 2 3 13 SOLEN ID ON TORCHSW 4 TORCH PRI sw on foss TORCH SW 15 15 1515 AL PY 1 TORCH SW 16 16 he 17 17 07 ATC MALE POT HIGH 18 18 18 18 J23 CONNECTOR 5 POT WIPER 19 19 POT LOW 20 20 20 20 28VAC A RECEIVER GATE DRIVE B RTNI21 21 BI TEST 1 GATE DRIVE A RTN 23 23 423 23 28 CONN GATE DRIVE 24 24 24 24 FACTORY INSTALLED OPTIONAL OUT SENSE 25 25 25 25 ronen MOUNTED GAS SOLENOID CURRENT SENSE 26 26 26 26 See eee CURRENT SENSE 27 27 27 27 CURRENT SENSE 28 28 28 28 F2 0 9A J24 P24 CURRENT SENSE 29 29 29 29 RESETABLE 7111 98 SOLENOID ai 5 PRESS GOOD 4a 4 PRESSURE 1 33 33 33 33 515 215 PS1 SWITCH K5 CLOSED WHEN TIP VOLTS 36 36 36 36 PRESSURE LOGIC EXTENDER MAIN BOARD WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED
49. IONS OF CIRCUITRY INSIDE PCB BLOCKS IS FOR REFERENCE ONLY OPTIONAL AUTOMATION INTERFACE CONNECTIONS B PLUGS INTO J27 ON MAIN BOARD ALTERNATE 20 PIN HEADER Lm 20 POSITION TERMINAL STRIP LED PCB 1 1 43 DE nn 212 2 2 421818 2 2 5 5 20120 1 1919 2 1819 2 1 TORCH SWITCH 2 1717 4 os Ekon ae INTERFACE 15115 SUO MONE 1 13 13 8 jo e cli 1212 Hn 10 DIVIDED OUTPUT ADAPTER HARNESS USED P41 J1 hr WHEN REMOTE CURRENT TcsR 919 12 CONTROL IS USED WITH 2 2 5 common 8 8 13 C i AUTOMATION HE IE REMOTE CURRENT CONTROL REPLACES CONNECTIONS asal 5 5 16 FROM J27 J14 151 818 TORCH SW HE 17 nc COMMON Le re NEG 19 8 8 1 5 Dla CPC HOUSING 1 41 9 TORCH switch ok MOVE 12 8 EE sen 1 1 OUTPUT INDUCTOR 1 Et voLts 4 44 2e REN PM Se ie mE PONT L1 D RECEIVER y ATC MALE CONNECTOR E64 E64 E35 E62 T E49 E45 E35 esx Eet Et E62 E430 0 OOo R PILOT D Vo H E37 CURRENT SENSE 2 JUMPER E N 57 E58 WORK E E58 E62 MODE SW RAROFF 52 74 51 5 P40 14 12 12V0C
50. NEVER use replaceable element fuses like UL Class H or one time fuses like UL Class K5 Manual 0 4669 A 1 APPENDIX APPENDIX 2 SEQUENCE OF OPERATION BLOCK DIAGRAM ACTION ACTION ACTION ACTION Close external ON OFF switch to ON RUN RUN disconnect switch Rapid Auto Restart SET switch to RUN EE RESULT Rapid Auto Restart RESULT SET switch AC indicator w ON to SET am Power to system Fan s ON for most applications 00 or to GAS indicator RESULT Rapid 4 when input pressure is adequate for power supply operation Power circuit ready Gas flows to set pressure for gouging trimming or expanded metal applications RESULT Gas flow stops ACTION Connect work cable to workpiece Set output amperage ACTION RESULT Torch moved away from work while System is ready still activated for operation RESULT Main arc stops Pilot arc automatically ACTION restarts Protect eyes and activate torch RESULT PILOT ARC Gas flows briefly then stops Gas restarts ACTION Torch moved within transfer distance of workpiece RESULT DC indicator ON Pilot arc established Main arc transfers Pilot arc off ACTION Release torch trigger RESULT ACTION ACTION Main arc stops Unplug input Gas flow stops after post flow ON OFF switch power cord or to OFF O open external d
51. P2 LT LL 03 94 C 112 sl Ra D4 TP2 R27 CT LL R73 E me tL md RS 1 1 05 c28 E LE R29 R95 md sd 1 Taso D30 ws 1 UE 041 CoO TI sm Er mis Zi 151 LOGIC PCB D De Ex te 331 Ld E O idi 2 mem LL 4 EU mI C eL pa RS 1 H D42 d us nfs H co 110 TP10 e 7 5 9 ls c54 LL A LTA 5 025 Art A 04641 TP8 TP7 Logic Board Layout TROUBLESHOOTING 4 8 Manual 0 4669 G Gas continues to flow with RUN RAPID AUTO RESTART SET switch in RUN position 1 Damaged gas solenoid a Turn the front panel ON OFF switch to OFF Ifgas continues to flow debris from the air line is preventing the solenoid from closing Clean or replace the solenoid 2 Faulty RUN RAPID AUTO RESTART SET switch a Put switch in SET position Disconnect wire harness connector from Main PC Board recep tacle J18 Check continuity through wire har ness sockets 7 and 8 If no continuity replace switch 3 Faulty Logic PCB a Measure for approximately 12 vdc between P1 7 and TP 1 on the Logic PC
52. POT LED PC Board Signals 14 1 from Main PC Board J27 1 Pot High 142 Main PC Board J27 2 Pot Wiper 143 from Main PC Board J27 3 Pot Low Jl44 12vdc 27 4 J145 Logic Low Signal for AC OK Indicator from Logic PC Board J27 5 J146 Logic Low signal for GAS Indicator from Logic PC Board J27 6 J147 Logic Low Signal for TEMP Indicator from Logic PC Board J27 7 14 8 Logic Low Signal fro DC Indicator from Logic PC Board J27 8 D4 Front Panel AC Indicator _ FrontPanel GAS Indicator D6 Front Panel TEMP Indicator Front Panel DC Indicator APPENDIX A 8 Manual 0 4669 APPENDIX 7 IGBT CIRCUIT PC BOARD LAYOUT Manual 0 4669 r J3 __ 97 Ell gg 019556197 95 C23 244 1 2424 42 4 62 to role 2 pa OL 9 1 t2i gt C2E1 E2 18 4 44 q Teg 61 Li Li J2 gt 8 mg V ey L u Art A 04569 A 9 APPENDIX APPENDIX 8 OUTPUT DIODE PC BOARD LAYOUT 2 2 16 zd Fa 16 7 15 O O 3 7 15 3 9 TPUT DIODE GUTPUT DIODE BD ES ce a a w N w E60 E60 191757 C3 E56 Art A 04570 APPENDIX A 10 Manual 0 4669 APPENDIX 9 OUTPUT BOARD WIRING DIAGRAM To Torch
53. Precau tions in Section 1 Be sure the operator is equipped with proper gloves clothing and eye and ear pro tection Make sure no part of the operator s body comes into contact with the workpiece while the torch is activated Sparks from the cutting process can cause damage to coated painted and other surfaces such as glass plastic and metal Handle torch leads with care and protect them from damage A Piloting Piloting is harder on parts life than actual cutting be cause the pilot arc is directed from the electrode to the tip rather than to a workpiece Whenever pos sible avoid excessive pilot arc time to improve parts life Torch Standoff Improper standoff the distance between the torch tip and workpiece can adversely affect tip life as well as shield cup life Standoff may also significantly affect the bevel angle Reducing standoff generally results in a more square cut Edge Starting For edge starts hold the torch perpendicular to the workpiece with the front of the torch tip at the edge 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 Direction of Cut The plasma gas stream swirls as it leaves the torch The purpose of the swirl is to maintain a smooth col umn of gas The swirl effect results in one si
54. ain Printed Circuit Board Layout Logic PCB NotShown TROUBLESHOOTING 4 10 Manual 0 4669 4 08 Pilot Arc Problems A WARNING The following tests must be performed with the power supply connected to primary input power There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair without proper training in power elec tronics measurement and troubleshooting tech niques Locate your symptom below A Torch will not pilot gas flows AC indicator s ON GAS TEMP 2 and DC indicators OFF 3 Art A 03988 uet j 1 Gaspressure is below power supply minimum require ment a Adjust gas pressure per pressure setting label on power supply 2 Upper O ring on torch head is in wrong position a Removeshield cup from torch check position of upper O ring Correct if necessary Upper Groove with Vent Holes Must Remain Open Upper O Ring in Correct Groove Threads Lower O Ring Art A 03725 Manual 0 4669 4 11 3 Faulty IGBT s a Measure between the following points on the IGBTs e IGBT E4to E10 E10 to E20 e IGBT B E23 to E27 E27 to E30 Voltage should be approximately 20 vdc before the start signal is active If voltage measures greater than 100 vdc when the start signal is active replace the respective IGBT s B Torch will not pilot RUN
55. amp Mounting Screws 7 7500 1 Bracket Filter Mounting Not Shown 9 7535 1 DualStage Air Filter Assembly 9 7527 1 Replacement First Stage Cartridge 9 1021 1 Replacement Second Stage Cartridge 9 1022 NotShown 1 Extended Work Cable 50 ft 15 2m 9 8350 1 WheelKit 9 8331 1 Nylon DustCover 9 7072 Filter Element Cat No 9 7741 Sprin idi First amp Second O ring Stage Cat No 9 7743 Assembled Filter Cartridges as marked Cover Art A 02942 Barbed amp Fitting Jg Art A 02476 Single Stage Filter Kit Two Stage Filter Kit PARTS LISTS 6 8 Manual 0 4669 PATENT INFORMATION The following parts are licensed under U S Patent No s 5120930 and 5132512 Catalog Number 9 8235 9 8236 9 8237 9 8238 9 8239 9 8244 9 8245 Manual 0 4669 Description Shield Cap Drag 50 60A Sheild Cap Drag 70 100A Shield Cup Body Shield Cap Machine 50 60A Shield Cap Machine 70 100A Shield Cap Drag 40A Shield Cap Machine 40A 6 9 PARTS LISTS This Page Left Blank PARTS LISTS 6 10 Manual 0 4669 APPENDIX 1 INPUT WIRING REQUIREMENTS CutMaster 151 m Wiring Specifications Powerinput E IPAE EA Fuse Amps Wire Non CSA Wire CSA Volts 1 Ph 3 Ph 1 Ph 3 Ph 1 Ph 3 Ph 208 50 01 4 4 cens S 230 50 na 6 4 230 60 212 92 10 6 4
56. ater table unless the hydrogen gas can be eliminated or dis sipated Trapped hydrogen gas that is ignited will cause an explosion Aho Noise can cause permanent hearing loss Plasma arc pro cesses can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent per manent loss of hearing To protect your hearing from loud noise wear pro tective ear plugs and or ear muffs Protect others in the workplace Noiselevels should be measured to be sure the deci bels sound do not exceed safe levels e For information on how to test for noise see item 1 in Subsection 1 03 Publications in this manual GENERAL INFORMATION m PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin The plasma arc process produces very bright ultra violet and infra red light These arc rays will damage your eyes and burn your skin if you are not properly protected To protect your eyes always wear a welding hel met or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to pro tect your skin from the arc rays and sparks Keep helmet and safety glasses in good condition Replace lenses when cracked chipped or dirty Protect others in the work area from the arc rays Use protective booths screens or shields Use the shade of lens as suggested in the following per ANSI ASC Z49 1 Minimum P
57. ates operating power is present in the unit 5 TEMP indicator turns on when internal sensors detect temperatures above normal limits 6 GAS indicator Indicates adequate gas pressure for power supply operation NOTE Minimum gas pressure for power supply opera tion is lower than the minimum for torch opera Hon 7 DC indicator Indicates DC power output circuit is active Torch must be activated TROUBLESHOOTING B Initial Setup Conditions 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 iden tify the possible symptom s and the defective circuit After repairs are complete run the following tests again to verify that the unit is fully operational 1 Connect gas supply to rear of Power Supply 2 Turn on gas supply and set operating pressure per pressure setting label on power supply NOTE Minimum gas pressure for power supply operation is lower than the minimum for torch operation 3 Setthe PowerSupply controls as follows ON OFF switch to OFF Down RUN RAPID AUTO RESTART SET switch to SET Down CURRENT control A to maximum C Main Input and Internal Power Tests 1 Connect main AC power to the unit 2 Setthe PowerSupply ON OFF switch to ON up and note the following AC indicator 7 is steady ON Main PCB Relay energizes pulling in main inpu
58. bsection 5 02 A Locate and label the input power cable connections and disconnect the cable Unthread the retaining nuton the Input CableStrain Relief on the inside of the Rear Panel and remove the Input Power Cable from the unit Install the replacement Input Power Cable by reversing the above steps The Input Power Cable ground wire requires a ring terminal SERVICE 5 18 Manual 0 4669 D Rear Panel Replacement A Disconnect primary input power and the gas supply at the source and bleed down the system before performing this procedure 1 Remove the cover per subsection 5 02 A Remove the primary input power cable per section 5 04 Remove the Regulator Filter Assembly per section 5 05 A Remove two bolts at the bottom corners of the Rear Panel Remove one nut ona stud on the inside of the Rear Panel at the rear edge of the center chassis Replace the Rear Panel by reversing the above steps B pM Ifnot already done attach the data tag s provided with the replacement Rear Panel Position these as on the original Rear Panel Manual 0 4669 5 19 SERVICE 5 06 Right Side Internal Parts Replacement A Fan Replacement M1 M2 D N 9 Remove the power supply cover per Section 5 02 A Label then carefully remove the wiring connectors from the terminals on the Fans Disconnectthe Work Cable from terminal E61 onthe Power Output Board Remove one bolt from the Front Panel of t
59. ce of any Thermal Dynamics product This warranty is invalid if the Thermal Dynamics product is sold by non authorized persons Effective March 2 2004 GENERAL INFORMATION 1 8 Manual 0 4669 SECTION 2 INTRODUCTION 2 01 Scope Of Manual This manual provides service instructions for the CutMas ter 151 Plasma Cutting Power Supply Information in this manual is particularly applicable to the troubleshoot ing 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 proce dures and basic troubleshooting refer to Operating Manual 0 4668 Read both the operating manual and the service manual thoroughly A complete understanding of the capabilities and functions of this equipment will assure obtaining the performance for which it was designed The CutMaster 151 Power Supply is available for the following input voltages 208 230 Volt Single Phase 400 Three Phase 460 Volt Three Phase 600 Volt Three Phase The 400 and 460 Volt Three Phase units may be converted forSingle Phase input power with a change of input power cord This Service Manual covers all types Particular attention is required in the Trouble Shooting Section Section 4 to ensure that the technician selects the proper test points and measurements for the Power Supply being serviced Manual 0 4669 2 02 General
60. d J1 5 rh lle s To Auto Interface Les me Board J1 6 ie 1 2 To PCB e Transformer 9 e le or to Optional Remote M Current Control To Logic Board via Connector To Main Transformer EL CO MAIN PCB ASSEMBLY 19X2197 460V 1912190 208 230V 19X2198 400v 19x2199 600V Qs Art A 04568 Heat Sink ToInput Temp Sensor Contactor If installed in conjuction Automation Interface Board is not installed in all units with Automation Interface PC Board Manual 0 4669 A 7 APPENDIX APPENDIX 6 LED POT PC BOARD LAYOUT J14 n D4 Ga 8 5 314 eem m 01034 Lo em fo Lo OF2c 705 ur R5 D8 J LO lt R4 g 26 OL Co 2 R2 R3 D7 A 03712
61. de 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 TROUBLESHOOTING E Dross 42 When dross is present on carbon steel it is commonly referred to as either high speed slow speed or top dross Dross present on top of the plate is normally caused by too great a torch to plate distance Top dross is normally very easy to remove and can often be wiped off with a welding glove Slow speed dross is normally present on the bottom edge of the plate It can vary from a light to heavy bead but does not adhere tightly to the cut edge and can be easily scraped off High speed dross usually forms a nar row bead along the bottom of the cut edge and is very difficult to remove When cutting a troublesome steel it is sometimes useful to reduce the cutting speed to produce slow speed dross Any resultant cleanup can be accomplished by scraping not grinding Parts In Place Circuit The power supply connects to Models SL60 or SL100 Torches Parts In Place circuitry in the power supply checks for the presence of torch consumable parts in the torch head When the shield cup is properly in stalled there is a slight gap between the shield cup and the torch handle Gas vents through this gap as part of normal operation Do not attempt to force the shield cup to close this gap Forcing the shield cup against the torch head or torch handle can damag
62. dress 82 Benning Street West Lebanon New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive European Council Directive 73 23 EEC as amended by Council Directive 93 68 EEC and to the National legislation for the enforcement of this Directive The equipment described in this manual conforms to all applicable aspects and regulations of the EMC Directive Euro pean Council Directive 89 336 EEC and to the National legislation for the enforcement of this Directive Serial numbers are unique with each individual piece of equipment and details description parts used to manufacture a unit and date of manufacture National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements Among them are CSA Canadian Standards Association standard C22 2 number 60 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used CENELEC EN50199 EMC ProductStandard for Arc Welding Equipment ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting equipment and associ ated accessories For environments with increased hazard of electrical shock Power Supplies bearing the mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips if equipped wit
63. e torch components Common Cutting Faults 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 Main Arc Extinguishes a Cutting speed too slow b Torch standoff too high from workpiece c Cutting current too high d Work cable disconnected e Worn torch parts f Non Genuine Thermal Dynamics parts used Manual 0 4669 3 Excessive Dross Formation a Cutting speed too slow b Torch standoff too high from workpiece c Worn torch parts d Improper cutting current Non Genuine Thermal Dynamics parts used 4 Short Torch Parts Life a Moisture in air source b Exceeding system capability material too thick c Excessive pilot arc time d Gas pressure too low e Improperly assembled torch Incorrect torch parts for the operation Non Genuine Thermal Dynamics parts used 4 05 Troubleshooting Guide General Information A WARNING There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshoot ing techniques 2 4 A General Information This Section covers advanced troubleshooting which re quires power supply disassembly and live measurements Advanced troubleshooting and repair of this unit is a pro cess which should be undertaken only by t
64. e replacement Filter Element open side first Replace Housing on Cover D N Reattach gas supply NOTE If unit leaks between housing and cover inspect the O Ring for cuts or other damage SERVICE 5 2 Manual 0 4669 C Optional Two Stage Filter Element Replacement The Two stage filter is an option When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unacceptable Refer to Section 6 Parts List for replacement filter element catalog number Always turn off the air supply and bleed down the system before disassembling the Filter Assembly as injury could result 1 Shutoffprimary input power 2 Shutoffairsupply and bleed down system Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely 4 Note the location and orientation ofthe old Filter Elements 5 Slide out the old Filter Elements First amp Second Stage Cartridges as marked Art A 02942 Optional Two Stage Filter Replacement 6 Slide the replacement Filter Elements into the Filter Assembly with the same orientation as noted in Step 4 above 7 Hand tighten the two bolts evenly then torque each bolt to 20 30 in Ibs 2 3 3 4 Nm Improper torque may damage the gasket 8 Slowly apply air pressure to the assembly checking for leaks NOTE A small amount of air leakage from the bottom fitting is normal Man
65. eatsink Shroud It should not be moveable Re install the power supply cover Manual 0 4669 5 21 SERVICE E Output Diode PC Board Replacement Follow the antistatic instructions provided with the replacement part to prevent damage to the component 1 Remove cover per subsection 5 02 A Locate the Output Diode PCB s located within the Output Power PC Board on the right side of the power supply Carefully remove all wire connections to the Output Diode Board s Remove screw s securing Output Diode PC Board s to the Heatsink and remove board s from the Power Supply Use isopropyl alcohol and a clean rag to clean the heatsink Do not scratch or abrade the heatsink Rom Applya thermal pad tothe heatsink Secure in place with small pieces of masking tape The tape must cover no more than 1 4 6mm of the edge of the thermal pad Art A 04639 Output Diodes 7 Use isopropyl alcohol to clean the large flat surface on the back of the component 8 Secure replacement board as follows a Position the hardware at the bottom of a recess in the face of the diode Ensure that the washer is under the head of the screw s b Torque hardware to 17 in lb 1 9 Nm NOTE Failure to torque properly will cause component damage 9 Connect wires as follows SERVICE 5 22 Manual 0 4669 J39 140 utput Diodes TIT re Q m OO00000 0000000
66. ed by the catalog number shown B Returns If a product must be returned for service contact your distributor Materials returned without proper authorization will not be accepted 6 02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly as listed in the parts list for each type item Also include the model and serial number of the torch Address all inquiries to your authorized Manual 0 4669 6 1 PARTS LISTS 6 03 Major External Replacement Parts Item Qty 1 1 2 1 1 3 1 Description Cover with labels Rear Panel provide data tag information when ordering For 208 230 Volt Power Supplies Non CSA For 208 230 Volt Power Supplies CSA For 400 Volt 460 Volt and 600 Volt Power Supplies Tube roll handle Art A 03709 NOTE Illustration may vary slightly from unit PARTS LISTS 6 2 Catalog 9 8335 9 8323 9 8668 9 8322 9 7998 Manual 0 4669 6 04 Front Panel Replacement Parts Item Description Ref Catalog 1 1 Knob Fluted Skirted 9 8527 2 1 On Off Switch SW1 8 3258 3 1 Run Rapid Auto Restart Set Switch SW2 8 3259 4 1 Assembly Pot LED PC Board 9 8004 for RoHS 9 0045 5 1 Work Cable 4 AWG 20 Ft 6 1 m with Clamp 9 8336 Art A 04541 NOTE Illustration may vary slightly from unit Manual 0 4669 6 3 PARTS LISTS 6 05 Left Side Internal Component Replacement Parts Item 1 1
67. eep all fumes and gases from the breathing area Keep your head out of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the kind of metal being used coatings on the metal and the different processes You must be very careful when cutting or welding any met als which may contain one or more of the follow ing Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are using These MSDSs will give you the in formation regarding the kind and amount of fumes and gases that may be dangerous to your health For information on how to test for fumes and gases in your workplace refer to item 1 in Subsection 1 03 Publications in this manual Use special equipment such as water or down draft cutting tables to capture fumes and gases Do not use the plasma torch in an area where com bustible or explosive gases or materials are located Phosgene a toxic gas is generated from the vapors of chlorinated solvents and cleansers Remove all sources of these vapors This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth de fects and in some cases cancer Cal
68. efective power cord a Check that the input power cable is not defec tive or installed incorrectly Section 4 10 D il lustrates wiring connections 2 input contactor W1 stuck a Check contactor Replace if stuck B Main power line fuses blow immediately after the ON OFF Switch is turned on 1 Faulty Input Diode a Test Input Diode per Subsection 4 10 C repair as necessary 4 5 TROUBLESHOOTING C Fans do not operate all control panel indicators OFF 1 Front Panel ON OFF switch in OFF position a Placeswitch to ON up position 2 Main power disconnect open a Close main power disconnect 3 Torch is not properly connected to Power Supply a Check torch connections to Power Supply Tighten or adjust as needed 4 Shield cup not fully tightened on torch head a Check shield cup for proper installation Do not overtighten 5 Main power line fuses blown a Replace main power line fuses 6 Improper input power cable connections inside Power Supply a RefertoSystem Schematic and correct if needed 7 Defective input power cable a Replaceinput power cable 8 Fuseblown inside Power Supply a Replace internal Fuse per Subsection 5 06 A 9 Line voltage above 10 tolerance over voltage protec tion a Reduce line supply 10 Faulty Auxiliary Transformer refer to Appendix pages 28 VAC Circuit Diagram Measure for 28 VAC on Main PC Board from J23 1 to J23 3 a If voltage is not pr
69. eignements quant la quantit et la nature de la fum e et des gaz pouvant poser des dangers de sant Pour des informations sur la mani re de tester la fum e et les gaz de votre lieu de travail consultez l article 1 et les documents cit s la page 5 Utilisez un quipement sp cial tel que des tables de coupe d bit d eau ou courant descendant pour capter la fum e et les gaz N utilisez pasle chalumeau au jet de plasma dans une zone o se trouvent des mati res ou des gaz combus tibles ou explosifs Le phosg ne un gaz toxique est g n r par la fum e provenant des solvants et des produits de nettoyage chlor s Eliminez toute source de telle fum e Ceproduit dans le proc der de soudage et de coupe produit de la fum e ou des gaz pouvant contenir des l ments reconnu dans L tat de la Californie qui peuvent causer des d fauts de naissance et le cancer La s curit de sant en Californie et la code s curit Sec 25249 5 et seq ELECTRIQUE Les chocs lectriques peuvent blesser ou m me tuer Le proc d au jet de plasma requiert et produit de l nergie lectrique haute tension Cette nergie lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres personnes sur le lieu de travail GENERAL INFORMATION 14 Netouchez jamais une pi ce sous tension ou vive portez des gants et des v tements secs Isolez vous de la pi ce de
70. erminer s il existe des risques de sant Il faut communiquer aux op rateurs et au person nel TOUS les dangers possibles Afin d viter les blessures possibles lisez comprenez et suivez tous les avertissements toutes les pr cautions de s curit et toutes les consignes avant d utiliser le mat riel Composez le 603 298 5711 ou votre distributeur local si vous avez des questions __ et GAZ sant La fum e et les gaz produits par le proc d de jet de plasma peuvent pr senter des risques et des dangers de GENERAL INFORMATION Eloignez toute fum e et gaz de votre zone de respira tion Gardez votre t te hors de la plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les gaz Les sortes de gaz et de fum e provenant de l arc de plasma d pendent du genre de m tal utilis des rev tements se trouvant sur le m tal et des diff rents proc d s Vous devez prendre soin lorsque vous coupez ou soudez tout m tal pouvant contenir un ou plusieurs des l ments suivants antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre s l nium b ryllium mangan se vanadium Lisez toujours les fiches de donn es sur la s curit des mati res sigle am ricain MSDS celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS contiennent des rens
71. esent replace the Main PC Board J24 932 jog 983 E an ss T P E6 N Eus A 7 27 L E30 Input Diode mounts to center chassis TrA A Xe D beso E15 E7 J25 bv 19X2197 19X2190 2ch 230v 19X2198 10 m 19 2199 E20 J31 E23 E12 Art 04640 E4 Main Printed Circuit Board Layout logicboardnotshown TROUBLESHOOTING 46 Manual 0 4669 11 Faulty ON OFF switch 4 Faulty Temperature Sensor Switch Measure for 28 VAC on the Main PC Board be a Shut input power off Check IGBT Heatsink tween J18 5 to J18 6 Temp Sensor TS1 Disconnect wire connector P29 from terminal J29 on Main PC Board Check a If voltage is not present replace the ON OFF connector pins 1 and 2 for 10K ohm 25 at ambient temperature If resistance is not 1
72. ficient 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 assis tance 1 603 298 5711 2 1 INTRODUCTION This Page Left Blank INTRODUCTION 2 2 Manual 0 4669 SECTION 3 DESCRIPTION 3 04 Scope The purpose of this section is To familiarize the service technician with the capabilities and limitations of the equipment To provide an overall understanding which will allow the technician in turn to properly train customer operat ing personnel The power supply includes all control circuitry electrical and air inputs and outputs pilot circuitry work cable with clamp and input power cable 3 02 Power Supply Specifications CutMaster 151 Power Supply Specifications 208 230 VAC 187 253 VAC Single Phase 50 60 Hz 00 VAC 360 440 VAC Single Phase 50 60 Hz 00 VAC 360 440 VAC Three Phase 50 60 Hz Input Power 60 VAC 414 506 VAC Single Phase 50 60 Hz 60 VAC 414 506 VAC Three Phase 50 60 Hz 600 VAC 517 632 VAC Three Phase 60 Hz Output Current 25 100 Amps Continuously Adjustable Power Supply Gas Filtering Ability CutMaster 151 Power Supply Duty Cycle Ambient Temperature 40 C 104 IEC TDC IEC TDC IEC TDC Rating Rating Rating Rating Rating Rating
73. g cutting up to 40 Amps for drag cutting with the torch tip in contact with the workpiece or for standoff cutting up to 100 amps 2 Front Panel Indicators e AC When lighted indicates AC input power is present in thepower supply GAS Whenlighted indicates that adequate input air pressure for power supply operation is present TEMP Whenlighted indicates the power supply is overheated DC Whenlighted indicates that power supply output circuits are active NOTE Minimum pressure for power supply operation is lower than minimum pressure for torch operation 3 03 Air Regulator Filter Assembly Specifications The following specifications apply to the Air Regulator Filter Assembly only 1 Operating Pressure 65 psi 4 5 bar 2 Maximum input air supply pressure 125 psi 8 6 bar Manual 0 4669 3 3 DESCRIPTION This Page Left Blank DESCRIPTION 3 4 Manual 0 4669 SECTION 4 TROUBLESHOOTING 4 01 Introduction This section provides service diagnostics for the CutMas ter 151 Power Supply allowing the Technician to iso late any faulty subassemblies Refer to Section 5 Repairs amp Replacement Procedures for parts replacement instruc tions Under no circumstances are field repairs to be attempted on Printed Circuit Boards or other subassemblies of this unit Evidence of unauthorized repairs will void the fac tory warranty NOTE The troubleshooting contained in this manual is for the P
74. h properly installed standoff guides Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac turing process This is to ensure the product is safe when used according to instructions in this manual and related industry standards and performs as specified Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications Thermal Dynamics has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative Steve Ward Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley Lancashire England PR6 78 Manual 0 4669 1 7 GENERAL INFORMATION 1 08 Statement of Warranty LIMITED WARRANTY Subject to the terms and conditions established below Thermal Dynamics Corporation warrants to the original retail purchaser that new Thermal Dynamics CUTMASTER 15 plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship Should any failure to conform to this warranty appear within the applicable period stated below Thermal Dynamics Corporation shall upon notification thereof and substantiation that the product has been stored operated and maintained in accordance with Thermal Dynamics specifications instr
75. he Power Supply near the Control Panel Pull the Front Panel slightly away from the Power Supply Remove nut from a stud at the bottom of the Fan Assembly Panel Lift the Fan Assembly Panel and pull it out of the Power Supply Remove two bolts per Fan Set the Fan s aside Install the replacement Fan Assembly as follows a Fasten Fan s in position with the wiring connectors at the bottom of the Fan s NOTE Only two screws are needed to attach the Fan to the Fan Panel They can be installed in any two holes provided they are opposite each other For grounding purposes one of those screws must be installed with a star washer b Place the Fan Assembly Panel in position in the Power Supply 1 The inner edge of the Panel has tabs that engage slots in the center chassis Ensure that these tabs fully engage in the chassis 2 Press Panel downward Press the bottom flange fully against the bottom panel of the Power Supply Ensure that the hole in the bottom flange of the Fan Assembly Panel engages the mounting stud c Replace nuton the bottom mounting stud d Ensure that the Fan Panel s top flange is fully against the top forward edge of the Heatsink Shroud e Press front panel of the Power Supply against the Fan Panel and fasten in place with the bolt removed in Step 2 f Secure the nut on the stud at the bottom of the Fan Panel Re connect the wires to the Fan Assemblies 10 Pass the Work Cable through the hole
76. hose familiar with high voltage high power electronic equipment If major complex subassemblies are faulty the faulty sub assembly must be returned for repair NOTE Follow all instructions as listed and complete each in the order presented Manual 0 4669 The troubleshooting guide has subsections as follows Section 4 06 Circuit Fault Isolation Section 4 07 Main Input and Internal Power Prob lems Section 4 08 Pilot Arc Problems Section 4 09 Main Arc Problems Section 4 10 Test Procedures Subsection 4 10 includes specific test procedures and in dicator status identification tables The subsection is ref erenced by the troubleshooting guide for the specific test to be performed The Power Supply is available for sev eral input voltages The technician must select the proper test points and measurements for the Power Supply being serviced B How to Use the Troubleshooting Guide The following information is a guide to help the Service Technician determine the most likely causes for various symptoms This guideisset up in the following manner 1 Perform operational check s on the equipment to iso late problem to possible circuit s per Subsection 4 06 Circuit Fault Isolation 2 Determine symptom and isolate to defective assem bly using the following format X Symptom Bold Type Any Special Instructions Text Type 1 Cause Italic Type Check Remedy Text Type Locate your symptom in the appr
77. ifornia Health amp Safety Code Sec 25249 5 et seq A SHOCK Electric Shock can injure or kill The plasma arc process uses and produces high voltage electrical energy This electric energy can cause severe or fatal shock to the op erator or others in the workplace Never touch any parts that are electrically live or hot GENERAL INFORMATION Wear dry gloves and clothing Insulate yourself from the work piece or other parts of the welding circuit Repair or replace all worn or damaged parts Extra care must be taken when the workplace is moist or damp Install and maintain equipment according to NEC code refer to item 9 in Subsection 1 03 Publica tions Disconnect power source before performing any service or repairs Read and follow all the instructions in the Operat ing Manual Ay AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the plasma arc Be sure there is no combustible or flammable ma terial in the workplace Any material that cannot be removed must be protected Ventilate all flammable or explosive vapors from the workplace Do not cut or weld on containers that may have held combustibles Provide 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 under water or while using a water table DO NOT cut aluminum alloys underwater or on a w
78. isconnect RESULT 9M RESULT All indicators off No power to system ower supply fan s shuts off Art A 03706 APPENDIX A 2 Manual 0 4669 APPENDIX 3 LOGIC PC BOARD LAYOUT D13 TP6 D33 or coc dr _ TP4 ss LLJ 1 C36 R70 O mt TT TP2 eee mm Ld 01 7 LL R73 C23 1 1 89 rj LL 2 029 C56 ne LL 000 md _ RIZ ES 1 BE D30 ws 151 LOGIC ASSEMBLY 92 m0 22 O D m TP9 emm mST us TES p 1 p24 D31 LL 6 CIF 540 paz TP10 R10 us tis nsf t25 3B 5 TP1 025 0 TP3 eL WE 35 7 1 TP11 LL IN 3 TP TP7 Art A 04641 TP5 D25 8 Logic Board Signals P1 28 Current Sense Return P1 1 12vdcfrom Main Power P1 29 CurrentSense Return P1 2 12vdcfrom Main PCB P1 30 DCCom 1 3 DCCom 1 31 DCCom 1 4 DCCom P1 32 Not Used 15 MC1ONsignal P1 33 ISense P1 6 P1 34 Not Used 1 7 RUN SET Signa
79. l Logic Low for SET P1 35 Not Used 8 LogicLow PS1 Pressure Switch P1 36 TipVolts closed Pressure OK P1 9 Logic Low TS1 Closed OVERTEMP PEU P1310 LogicLow CSR 7 5 DRAGON 1 11 Logic Low Gas ON D33 SWITCHON 1 12 Logic Low DCOK P1 13 Logic Low OVTEMP TEST POINTS P1 14 Logic Low ACOK TP Common P1 15 Logic Low Torch Switch TP2 Current Demand Signal FT d ee Return TP 3 Converter Enable v gic Low 12 TP 4 CSR Logic Low P1318 Logic Low High TP 5 Not ie P1 19 Logic Low High TP 6 Fault Logic Low P1 20 PotLow TP 7 DC OK Logic Low P121 Gate Drive B Return TP 8 Tip Sense P1 22 Gate Drive B TP 9 Current Sense P1 23 Gate Drive A Return TP 10 Gate Drive A P1 24 Gate Drive A TP 11 Gate Drive B P1 25 OutSense P1 26 Current Sense P1 27 Current Sense Manual 0 4669 A 3 APPENDIX APPENDIX 4 MAIN POWER PC BOARD LAYOUT J33 Input Diode J18 E5 EO k ae D I J43 mounts to center chassis E15 E7 E27 E30
80. ly cover per Section 5 02 A 2 Disconnect the wires on the rear of the Switch Note the location of each wire shown Art A 03906 3 Squeeze together the clips on the top and bottom of the Switch then remove the switch through the Front Panel 4 Install the replacement Switch by reversing the above steps 5 Reinstall the power supply cover D POT LED PC Board Replacement Remove the power supply cover per Section 5 02 A Remove Current Knob Disconnect wire harness Connector from POT LED PC Board Remove PC Board from standoffs Install the replacement POT LED PC Board by reversing the above steps D Reinstall the power supply cover SERVICE 5 8 Manual 0 4669 5 04 Left Side Internal Parts Replacement A Fuse F1 Replacement 1 2 3 Remove the power supply cover per Section 5 02 A Locate the internal fuse on the left side of the center chassis Replace the fuse A replacement fuse is located inside the power supply Refer to Section 6 Parts Lists for replacement fuse catalog number Reinstall the power supply cover Internal Fuse Location Manual 0 4669 5 9 SERVICE B Main Input Contactor W1 Replacement Remove the power supply cover per Section 5 02 A Labelall wires connected to the Input Contactor Disconnect wires to the Input Contactor from the input cable Disconnect all other wires connected to the Input Contactor Removethe two nuts and washers securing the
81. nal Standards Institute 1430 Broadway New York NY 10018 1 04 Note Attention et Dans ce manuel les mots note Avertissement attention et avertissement sont utilis s pour mettre en relief des informations caract re important Ces mises en relief sont classifi es comme suit NOTE Toute op ration proc dure ou renseignement g n ral sur lequel il importe d insister davantage ou qui contribue l efficacit de fonctionnement du syst me Manual 0 4669 ATTENTION Toute proc dure pouvant r sulter l endommagement du mat riel en cas de non respect de la proc dure en question SSEMENT Toute proc dure pouvant provoquer des blessures de l op rateur ou des autres personnes se trouvant dans la zone de travail en cas de non respect de la proc dure en question 1 05 Precautions De Securite Importantes SSEMENTS L OP RATION ET LA MAINTENANCE DU MAT RIEL DE SOUDAGE AU JET DE PLASMA PEUVENT PRESENTER DES RISQUES ET DES DANGERS DE SANTE Coupant l arc au jet de plasma produit de l nergie lectrique haute tension et des missions magn tique qui peuvent interf rer la fonction propre d un pacemaker cardiaque les appareils auditif ou autre mat riel de sant electronique Ceux qui travail pres d une application l arc au jet de plasma devrait consulter leur membre professionel de m dication et le manufacturier de mat riel de sant pour d t
82. nd some additional pieces Note the correct assembly of the filter spool then remove the filter from the spool and either clean it or replace it 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 Assembly Filter Element Art A 02995 Regulator Filter ElementReplacement Reinstall the bowl Turn on the air supply Manual 0 4669 5 1 SERVICE B Single Stage Filter Element Replacement TheSingle Stage Filter is an option ThePowerSupply 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 Elementto dry Refer to Section 6 Parts List for replacement filter elementcatalog number 1 Remove power from power supply 2 Shutoffairsupply and bleed down system before disassembling Filter to change Filter Element 3 Disconnect gas supply hose 4 Turn the Cover counter clockwise and remove it from the Filter Housing The Filter Element is located inside the Housing Housing Filter Element Cat No 9 7741 pc O ring Cat No 9 97743 Assembled Filter Cover 2 Barbed Fitting Art 02476 Single Stage Filter Element Replacement Remove the Filter Element from the Housing and set Element aside to dry Wipe inside of housing clean then insert th
83. nel turns ON Anopen circuit voltage of approximately 230 to 300 vdc depending on input power is produced when the switching of the IGBTs in the Main PC Board is turned ON by an INV ON signal from the Logic PC Board A circuit on the Logic PC Board monitors the output volt age When the output voltage drops below 60 vdc indi cating a problem exists the Logic PC Board sends a sig nal which turns OFF the INV ON Enable signal This happens in less than 50 milliseconds When the torch is activated gas will flow for approxi mately two seconds before DC is established indicated on the front panel Then the gas shuts off briefly The gas flow then starts again and the torch starts a pilot arc When the torch is close to the workpiece the cutting arc transfers to the work The resulting current is sensed by the Current Sense circuit resulting in the demand level changing from pilot current to the main current control setting and then the main cutting arc starts If the torch is removed from the workpiece while the torch switch is still pressed the main arc extinguishes and the pilot arc automatically restarts CutMaster 151 Logic Board Indicators Meaning Inverter ON D33 Torch Switch ON Drag Circuit ON 41 TROUBLESHOOTING 4 04 Common Operating Problems ves Disconnect primary power at the source before dis assembling the power supply torch or torch leads Frequently review the Important Safety
84. nings 1 1 1 02 Important Safety Precautions 1 1 1 2 1 04 Note Attention et Avertissement 1 3 1 05 Precautions De Securite Importantes 1 3 1 06 Documents De Reference ss 1 5 1 07 Declaration of 1 7 1 08 Statement of Warranty 1 8 SECTION 2 INTRODUCTION 2 1 2 01 Scope Of Manual ER edd 2 1 2 02 General Service Philosophy ur 2 1 2 03 Service 2 1 SECTION 3 DESCRIPTIONS DEED 3 1 3 011 S60D68 iiie E iai uctus dentate D Ed 3 1 3 02 Power Supply Specifications 3 1 3 03 Air Regulator Filter Assembly Specifications 3 3 SECTION 4 TROUBLESHOOTING Retroceder eg A Lu e veri es 4 1 2 01 4 1 4 02 Periodic Inspection amp Cleaning 4 1 4 03 SYSTEM cene nen eau cos E 4 1 4 04 Common Operating Problems 4 2 4 05 Troubleshooting Guide 4 3 4 06
85. nput Standard Symbols static frequency converter transformer rectifier DC output gt 2 Indicates input voltages for this power supply Most power supplies carry a label at the input power cord showing input DC voltage requirements for the power supply as built e Phase 3 Top row Duty cycle values IEC duty cycle value is calculated as specified by the International ElectroTechnical Commission Art A 03288 TDC duty cycle value is determined under the power supply manufacturer s test procedures Second row Rated cutting current values Third row Conventional load voltage values 4 Sections of the Data Tag may be applied to separate areas of the power supply APPENDIX A 14 Manual 0 4669 APPENDIX 13 TORCH PIN OUT DIAGRAMS A Hand Torch Pin out Diagram ATC Female Receptacle Front View Negative Plasma Negative iro u AY 3 White Switch 3 D E NEN en 20 ge 92 07 n A 03701 Machine Torch Pin out Diagram ATC Female Receptacle Front Vi Negative Plasma 8 Green poc 4 Switch ON Ll 1 JEN Gy _7 Green z open E M 1 21 7 2 PIP ATC Male Connector Front View W Pendant 4 2 Bano 2 a 2 6 Open 7 Se 5 5 SS 1 PIP 1 Black PIP APPENDIX Manual 0 4
86. nt L experience a d montrer que les filtres moins fonc s peuvent tre utilis s quand l arc est cach par moiceau de travail Le bruit peut provoquer une perte permanente de l ouie Les proc d s de soudage l arc de plasma peuvent provoquer des niveaux sonores sup rieurs aux limites normalement acceptables Vous d 4ez vous prot ger les oreilles contre les bruits forts afin d viter une perte permanente de l ouie Pour prot ger votre contre les bruits forts portez des tampons protecteurs et ou des protections auriculaires Prot gez galement les autres personnes se trouvant sur le lieu de travail e Il faut mesurer les niveaux sonores afin d assurer que les d cibels le bruit ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 Manual 0 4669 1 06 Documents De Reference Consultez les normes suivantes ou les r visions les plus r centes ayant t faites celles ci pour de plus amples renseignements 1 OSHA NORMES DE S CURIT DU TRAVAIL ET DE PROTECTION DE LA SANT 29CFR 1910 disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 2 Norme ANSI Z49 1 LA S CURIT DES OP RATIONS DE COUPE ET DE SOUDAGE disponible aupr s de la Soci t Am ricaine de Soudage American Welding Society 550 N W LeJeune Rd Miami FL 33126 3 NIOSH LA S CURIT
87. ntistatic instructions provided with the replacement part NOTE Follow the electrostatic discharge instructions provided with the replacement component to prevent damage to the component Thermal pads heatsinks and the large flat surface on the back of diodes and IGBTs must be kept clean Diodes and IGBTs must not be bent or allowed to pick up any foreign material A very clean installation between the module and the heatsink or chassis is essential for proper operation 1 Remove the power supply cover per Section 5 02 2 Turn the Power Supply onto its side 3 Locate the Input Diode mounted to the center chassis to the left of the Main Power PC Board Refer to Appendix pages for location and position 4 Label then remove all wire connections to the diode bridge being replaced Note the routing of wires Ensure that the wires are put back in the same place when installing the replacement bridge Keep the hardware for re use 5 Remove screws securing the bridge to the heatsink and remove the bridge from the Power Supply 6 Useisopropylalcohol and a clean rag to clean the chassis area behind the component being replaced Clean the large flat surface on the back of the replacement component Do not scratch or abrade the surface Manual 0 4669 5 11 SERVICE 7 Thethermal pad provided with the replacement part is a thin metal pad Remove any loose protective paper coverings from the pad NOTE Protective coverings must be
88. on power supply Fan M1 4 Faulty RUN RAPID AUTO RESTART SET switch fvoltageat 15 2 to J15 6 is correct replace up a Check continuity per Fan M2 5 Faulty Gas Solenoid circuit a Test Gas Solenoid circuit per Subsection 4 10 E repair as necessary 6 Faulty Logic Board a Replacelogic board Manual 0 4669 4 7 TROUBLESHOOTING RUN RAPID AUTO RESTART SET switch in RUN or RAPID AUTO RESTART position AC indicator gt ON TEMP GAS indicators OFF A XE 9 5 e 5 Faulty Components in Unit Measure for 12 vdc from wire 10 to wire 11 at the Gas Pressure Switch located on the right side of the unit If 12 vdc is present and pressure is above 50 psi 3 4 bar replace Gas Pressure Switch Solenoid Assembly Refer to Section 5 08 A If pressure is above 50 psi 3 4 bar and 12 vdc is not present replace the Logic PC Board o Remove one wire from the pressure switch Check for 0 vdc at Main PC Board pin J24 3 to J24 4 from the Logic PC Board Refer to Main PC Board Layout Ifless than a volt replace Logic PC Board 1 Gaspressure too low a Set operating pressure per pressure setting la bel on power supply 2005 r3 41 H2 D10 RES H3 TP4 R22 1 L 1 i ni 15 T
89. opriate Subsection Checkthe causes easiest listed first for the symptom Check the remedies listed for each cause Repairas needed being sure to verify that unit is fully operational after any repairs NOTES Many signals are transferred between Printed Cir cuit Board Assemblies on Cables If these cables become faulty they can then cause various prob lems Do not forget about these cables when troubleshooting While troubleshooting visually inspect the internal components for signs of overheating fractures and damage 4 3 TROUBLESHOOTING 4 06 Circuit Fault Isolation A Controls and Indicators 7 gt 60 TU a gt sg J Coo m ox 20 100 E 1 Art A 04490 1 ON OFF switch This switch controls AC power to the unit Up is ON down is OFF 2 RUN RAPID AUTO RESTART SET switch This switch controls gas flow to the torch Up is RUN for general torch operation Center position is RAPID AUTO RESTART for an uninterrupted restart when cutting expanded metal or in gouging or trimming op erations Down is SET for setting gas pressure and purging lines 3 Current control knob A This control regulates cur rent to the torch At output settings over 40 amps cir cuitry in the power supply automatically reduces out put current to 40 amps if the torch tip contacts the workpiece 4 AC indicator When lit indic
90. ower Supply only Troubleshooting other parts of the system is covered in the manuals for those products 4 02 Periodic Inspection amp Cleaning Procedures A WARNING Disconnect primary power and bleed down the sys tem before disassembling the torch leads or power supply To clean the unit open the enclosure per procedure in section 5 05 A Cover Removal and use a vacuum cleaner to remove any accumulated dirt and dust The unit should also be wiped clean If necessary solvents for cleaning electrical apparatus may be used Refer to the Appendix for maintenance schedule and pro cedures Manual 0 4669 4 03 System Theory A Logic PC Board Functions The Logic PC Board controls the timing and sequenc ing of the system It monitors gas pressure and power supply internal temperatures and controls the gas flow The Logic Board also controls the safety latch circuit After the ON OFF switch is closed on the front panel the AC Indicator turns on The GAS indicator is ON when there is sufficient gas pressure in the power supply to enable power sup ply operation NOTE Minimum gas pressure for power supply operation is lower than the minimum for torch operation When the unit is at idle the AC indicator lt gt on the Front Panel should be ON When the torch is acti vated the gas begins to flow After a brief preflow the INV ON signal is given and the DC indicator on the Front Pa
91. removed from the thermal pads Installing thermal pads with protective coverings in place will cause equipment damage or failure 8 Install replacement components as follows Power Supply Center Chassis Thermal Pad Art A 04609 InputDiodeReplacement a Applythethermal pad to the flat surface of the bridge Align the pad with the rectangular flat surface on the back of the device b Align the bridge with its mounting holes in the power supply chassis c Secure the bridge and rectangular pad to the chassis with the replacement screws and washers 9 Torque the diode mounting screws to 18 in lb 2 0 Nm NOTE Failure to torque properly will cause component damage 10 Usethehardware removed previously to re connect wires per the appropriate diagram Ensure thatthe star washers are in place between the screws and the wire ring terminals SERVICE 5 12 Manual 0 4669 O T 400V e 415V Uni s 208 230V Units 460V Units Copper je e N 1 2 3 gt 3 mounts to center chassis mounts to center chassis ee oy
92. rmadyne Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park JIn Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Cigweld Australia 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7510 Thermadyne Italy OCIM S r L Via Benaco 3 20098 5 Giuliano Milan Italy Tel 39 02 98 80320 Fax 39 02 98 281773 Thermadyne International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 16062 Swingley Ridge Road IHERMAL DYNAMICS SLE MO 63017 By THERMAUYNES Telephone 636 728 3000 Email TDCSales Thermadyne com www thermadyne com
93. rotective 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 work piece 1 03 Publications Refer to the following standards or their latest revisions for more information 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Docu ments U S Government Printing Office Washington D C 20402 ANSI Standard Z49 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding So ciety 550 N W LeJeune Rd Miami FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Govern ment Printing Office Washington D C 20402 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCU PATION AND EDUCATIONAL EYE AND FACE PRO TECTION obtainable from American National Stan dards Institute 1430 Broadway New York NY 10018 ANSI Standard 741 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the Ameri can National Standards Institute 1430 Broadway New York NY 10018 Manual 0 4669 10 11 12 13 14 15 ANSI Standard Z49 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtain able from American National Standards Institute 1430 Broadway New York NY 10018 AWS Standard A6 0 WELDING AND CUTTING CON
94. rted power supply torch receptacle Art A 03621 Turn Power Supply OFF Bleed down the system Disconnect the torch from the power supply Check the torch receptacle for continuity between the pilot connection and the negative plasma connection Refer to Appendix pages There should be no continuity 5 Shorted output power PC Board a Turn Power Supply OFF Bleed down the system Refer to Appendix pages Output Board Wiring Dia gram Check output power PC Board for continuity between terminals E35 and E64 If continuity isfound replace Output Power PC Board TROUBLESHOOTING 385 Jag Br J18 E5 eu lessons ELE IN FO 2 27 y yesssssassssossa J26 E27 Input Diode E30 mounts to center chassis E15 E7 J25 MAIN ASSEMBL 19X2197 4 1942190 x E10 1902198 ach 20 930 Art 04640 M
95. s en aluminium sous l eau ou sur une table d eau moins que le gas hydrog ne peut s chapper ou se dissiper Le gas hydrog ne accumul explosera si enflamm m Revo D ARC DE PLASMA Les rayons provenant de l arc de plasma peuvent blesser vos yeux et br ler votre peau Le proc d l arc de plasma produit une lumi re infra rouge et des rayons Manual 0 4669 ultra violets tr s forts Ces rayons d arc nuiront vos yeux et br leront votre peau si vous ne vous prot gez pas correctement Pour prot ger vos yeux portez toujours un casque ou un cran de soudeur Portez toujours des lunettes de s curit munies de parois lat rales ou des lunettes de protection ou une autre sorte de protection oculaire Portez des gants desoudeur et un v tement protecteur appropri pour prot ger votre peau contre les tincelles et les rayons de l arc Maintenez votre casque et vos lunettes de protection en bon tat Remplacez toute lentille sale ou comportant fissure ou rognure Prot gez les autres personnes se trouvant sur la zone de travail contre les rayons del arc en fournissant des cabines ou des crans de protection Utilisez la nuance de lentille qui est sugg r e dans le recommendation qui suivent ANSI ASC 749 1 Nuance Minimum Nuance Sugger e Courant Arc Protective Num ro Num ro Moins de 300 8 9 300 400 9 12 400 800 10 14 Ces valeurs s appliquent ou l arc actuel est observ claireme
96. se units for 400 Volt Three Phase units for 400 Volt Three Phase CE units Mounting Nut Pressure Gauge NOTE Illustration may vary slightly from unit PARTS LISTS Art A 03005 Catalog 9 7514 9 4414 9 7589 9 8596 9 8665 9 8593 9 8562 9 8553 9 5804 9 1045 Manual 0 4669 6 07 Right Side Internal Component Replacement Parts Item Qty 1 1 2 1 3 1 4 1 5 1 6 1 7 1 1 Description Assembly Pressure Switch Solenoid Assembly Pilot Board for RoHS Fan 220V 115 CFM Assembly Main Transformer for 208 230 Volt units for 400 Volt units for 460 Volt units for 600 Volt units Assembly Output Inductor Assembly Output Power PCB for RoHS Assembly Output Diode PCB Kit Output Diode Assembly Thermal Pad for RoHS NOTE Illustration may vary slightly from unit Manual 0 4669 IGBT Heatsink AA A CF Ref Sol1 Ps1 T5 L1 Heatsink Shroud Catalog 9 8329 9 8337 9 0070 9 7687 9 8345 9 8347 9 8346 9 8348 9 8591 9 8339 9 0078 9 8349 9 0050 Output Diode Heatsink Art A 04515 PARTS LISTS 6 08 Options and Accessories Oty 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 NotShown 9 7742 1 Two Stage Air Line Filter Kit Includes Hose
97. sed for mounting the IGBT module must be visible through the holes in the thermal pad pe Heatsink SN Art A 04642 ge sr Se b NS Pd 1 7 Heatsink N E 6 Securereplacement module s with the hardware removed previously Ensure that the washers under the heads of the screws 7 Torquescrew s to 22 in Ib 2 5 Nm NOTE Failure to torque properly will cause component damage SERVICE 5 14 Manual 0 4669 8 Secure replacement IGBT PC Board s with the hardware removed previously Ensure that the washers are under the heads of the screws Art A 04643 9 Torque screws to 22 in lb 2 5 Nm NOTE Failure to torque properly will cause component damage 10 Connect wires as shown uy MAIN PCB assEJav 191929 460V Art A 04644 11 Reinstall the cover Manual 0 4669 5 15 SERVICE E Main PC Board Replacement Follow theantistatic procedures provided with the replacement part 1 D oN 9 Remove the power supply cover per Section 5 02 A Remove the Logic PC Board and the extender board Removethe POT LED PC Board Disconnectall
98. sh 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 fol lowing Main cutting arc transfers to workpiece This completes the Main Arc Test If the above are all correct then the equipment should be operating properly If problems still persist then contact Technical Services If the torch does not function as noted then note the symp tom and proceed to Subsection 4 09 Main Arc Problems 4 07 Main Input and Internal Power Problems A Opening Power Supply Enclosure The cover of the Power Supply must be removed for ac cess to input power connections and test points Disconnect primary power at the source before as sembling or disassembling the Power Supply torch parts or torch and leads assemblies 1 Remove the upper screws securing the cover to the main assembly 2 Loosen but do not remove the lower screws NOTE There is a ground wire attached from the cover to the main body of the unit Manual 0 4669 3 Carefully lift the cover off the unit and remove thenut securing the ground wire to the side panel 4 Re install the cover by reversing the above steps Upper screws Lower Screws Lower Ground wire Art A 04510 Cover Removal Locate your symptom below A Main power line fuses blow as soon as main disconnect is closed 1 Input power cable installed incorrectly or d
99. sink Shroud Assembly The stud and nut on the bottom left edge fasten wire stay to the Power Supply Replace the grommets around the wire harnesses passing through right rearward edge of the Heatsink Shroud Reinstall the Pilot Board Reconnect the wires to the Pilot Board Reconnect the torch receptacle ground wire to the center chassis Replace the Pressure Switch Solenoid Assembly This assembly fits into a slot in the top horizontal surface of the Heatsink Shroud Anotched pin holds the assembly in place Connect the gas hose between the Regulator Assembly and the Gas Pressure Switch Solenoid Assembly 10 Connect wiring to the Output Power PC Board Refer to the Appendix pages for wiring layout 11 Replace the Power Supply rear panel per subsection 5 05 D This concludes the replacement procedures Manual 0 4669 5 25 SERVICE This Page Left Blank SERVICE 5 26 Manual 0 4669 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 LeftSide Internal Component Replacement Parts Section 6 06 Rear Panel Replacement Parts Section 6 07 RightSide Internal Component Replacement Parts Section 6 08 Options and Accessories NOTE Parts listed without item numbers are not shown but may be order
100. t contactor W1 TEMP Indicator is GAS Indicator is ON if input pressure is suffi cient for power supply operation NOTE Minimum gas pressure for power supply operation is lower than the minimum for torch operation DC indicator is OFF Gas flows Fans operate Set the Power Supply RUN RAPID AUTO RESTART SET switch to the RUN up position and note the following Gas flow stops This completes the Main Input and Internal Power Tests If the above are all correct then proceed to paragraph If not note the symptom and proceed to Subsection 4 07 Main Input and Internal Power Problems Manual 0 4669 D Pilot Arc Test 1 Activate the torch press torch switch on the handle send START signal from CNC Control or press the torch switch on the Remote Pendant to establish a pilot arc and note the following Gas flows Preflow delay approximately two seconds then DC indicator turns ON Pilot arc is established This completes the Pilot Arc Test If the above are all cor rect then proceed to paragraph E If the unit does not function properly then note the symptom and proceed to Subsection 4 08 Pilot Arc Problems E Main Arc Test Make sure the work cable is firmly connected to the work piece Activate the torch press torch switch on the handle send START signal from CNC Control or press the torch switch on the Remote Pendant to establi
101. te that the Pilot PC Board mounts with its printed text upside down Fasten the Pilot Board to the standoffs with the hardware removed previously Torque the hardware to 18 in Ibs 2 04 Nm Reconnect wires to the Pilot PC Board Wire 58 connects to terminal E58 wire 62 connects to terminal E62 Ensure thatthe wire harness connector is fully seated in receptacle J28 Reinstall the power supply cover D Pressure Switch Solenoid Assembly Replacement The Pressure Switch and Solenoid Valve are one Assembly Disconnect primary input power and bleed down the system 1 2 3 Remove the power supply cover per Section 5 02 A Disconnect the following wires a Wires 10 and 11 from the Pressure Switch Assembly b Wires 8 and 9 from the Solenoid Assembly Push the clip on the front of the Heatsink Shroud to the left to release the Solenoid Assembly Dislodge the Assembly from underneath the clip on the top of the Heatsink Shroud Push Clip to the left to release Solenoid Assembly Art A 03705 Release the hose from the Adapter Fitting on the input side of the Solenoid Assembly Hold a wrench or similar tool against the locking ring on the Fitting then pull on the hose to release it Release the hose from the Adapter Fitting on the output side of the Solenoid Assembly Install the replacement Pressure Switch Solenoid Assembly by reversing steps 2 5 Once installed the Solenoid Assem bly should fit securely on the H
102. that may react with the atmosphere This reaction can leave contaminants inside the torch Either of these conditions can lead to inconsistent performance or poor parts life Art 03791 O Ring SERVICE 5 4 Manual 0 4669 5 02 Power Supply Major External Parts Replacement Disconnect primary power to the system before disassembling the torch leads or power supply For replacement of parts not covered in this section instructions are provided with the replacement part A Cover Removal 1 Remove the upper screws which secure the cover to the main assembly NOTE There is a ground wire connection to the inside of the unit There is no need to disconnect the ground wire unless there is a need for more room to work Upper screws N Screws Lower Ground wire Art A 04510 2 Loosen but do notremove the lower screws then carefully pull the Cover up and away from the unit Manual 0 4669 5 5 SERVICE B Tube Handle Replacement 1 Remove the power supply cover per Section 5 02 A 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 Tube Handle 4 Witharubber mallet separate the two handle ends as shown below 5 Install the replacement Tube Handle by reversing the above steps 6 Reinstall thepower supply cover
103. travail ou des autres parties du circuit de soudage R parez ou remplacez toute pi ce us e ou endommag e Prenez des soins particuliers lorsque la zone de tra vail est humide ou moite Montez et maintenez le mat riel conform ment au Code lectrique national des Etats Unis Voir la page 5 article 9 D branchez l alimentation lectrique avant tout tra vail d entretien ou de r paration e Lisez et respectez toutes les consignes du Manuel de consignes Ao ET EXPLOSION Les incendies et les explosions peuvent r sulter des scories chaudes des tincelles ou de l arc de plasma Le proc d l arc de plasma produit du m tal des tincelles des scories chaudes pouvant mettre le feu aux mati res com bustibles ou provoquer l explosion de fum es inflammables Soyez certain qu aucune mati re combustible ou in flammable ne se trouve sur le lieu de travail Prot gez toute telle mati re qu il est impossible de retirer de la zone de travail e Procurez une bonne a ration de toutes les fum es inflammables ou explosives e Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des mati res combustibles Pr voyez une veille d incendie lors de tout travail dans une zone pr sentant des dangers d incendie Le gas hydrog ne peut se former ou s accumuler sous les pi ces de travail en aluminium lorsqu elles sont coup es sous l eau ou sur une table d eau NE PAS couper les alliage
104. ual 0 4669 5 3 SERVICE D Cleaning Torch Even if precautions are taken to use only clean air with a torch eventually the inside of the torch becomes coated with residue This buildup can affectthe pilot arc initiation and the overall cut quality of the torch A s Disconnect primary power to the system before disassembling the torch or torch leads DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft wet rag In severe cases the torch can be removed from the leads and cleaned more thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air CAUTION Dry the torch thoroughly before reinstalling E O Ring Lubrication An O ring the Torch ATC Male Connector requires lubrication on a regular basis depending on how frequently the torch is disconnected and re connected This will allow the O ring to remain pliable and provide a proper seal The O ring will dry out becoming hard and cracked if the O ring lubricant is not used ona regular basis This can lead to performance problems Itisrecommended to apply a very light film of O ring lubricant Catalog 8 4025 to the O ring on a weekly basis NOTE DO NOT use other lubricants or grease they may not be designed to operate within high temperatures or may contain unknown elements
105. uctions recommendations and recognized industry practice correct such defects by suitable repair or replacement This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose Thermal Dynamics will repair or replace at its discretion any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below Thermal Dynamics Corporation must be notified within 30 days of any failure at which time Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor LIMITED WARRANTY PERIOD Product Power Supply Components Torch and Leads Parts and Labor Parts and Labor CUTMASTER 51 CUTMASTER 81 CUTMASTER 101 CUTMASTER 151 This warranty does not apply to 1 Consumable Parts such as tips electrodes shield cups o rings starter cartridges gas distributors fuses filters 2 Equipment that has been modified by an unauthorized party improperly installed improperly operated or misused based upon industry standards In the event of a claim under this warranty the remedies shall be at the discretion of Thermal Dynamics
106. upr s dela National Fire Pro tection Association Batterymarch Park Quincy MA 02269 Norme 51B de la NFPA LES PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 Brochure GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIM S EN CYLINDRES disponible aupr s de l Association des Gaz Comprim s Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Norme CSA W117 2 CODE DE S CURIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Livret NWSA BIBLIOGRAPHIE SUR LA S CURIT DU SOUDAGE disponible aupr s de l Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 Norme AWSF4 1 de l Association Am ricaine de Soudage RECOMMANDATIONS DE PRATIQUES SURES POUR LA PR PARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERM DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 Norme ANSI Z88 2 PRATIQUES DE PROTECTION RESPIRATOIRE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 GENERAL INFORMATION Manual 0 4669 1 07 Declaration of Conformity Manufacturer Thermal Dynamics Corporation Ad
107. wire and cable connections to the Main PC Board including the connections from the three smaller PC Boards Referto the Main PC Board Wiring Diagrams in the Appendix pages if necessary Remove the two long Transformer screws securing the Auxiliary Transformer to the Center Chassis Remove the other screws securing the PC Board to the Center Chassis Carefully remove the original PC Board Install the replacement PC Board by reversing steps above It may be easier to install the PC Board if the Power Supply is turned on its right side first Torque the screws to 18 inch pounds 2 0Nm Screws securing the secondary transformer to the main PC Board must be torqued to 22 in Ibs 2 5 Nm LR 1 224 1 334 me mecs 7114 Secondary SV e Transformer MAIN PCB ASSEMBLY 19X2197 460V 19X2190 208 230

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