Thermal Dynamics CutMaster 38 Service
Contents
1. To PFC Inductor To On Off See NOTE Switch To Torch Receptacle To To Output Er Bridge 1 Inductor EN See NOTE To Bridge 2 NOTE Terminals E4 E11 and E18 are on the back of the PC Board Manual 0 2898 Work Cable er To Output Inductor A 3 Torch Ground To Ground APPENDIX APPENDIX 4 MAINTENANCE SCHEDULE This schedule applies to all types of non liquid cooled plasma cutting systems Some systems will not have all the parts listed and those checks need not be performed NOTE The actual frequency of maintenance may need to be adjusted according to the operating environment Daily Operational Checks or Every Six Cutting Hours Check torch consumable parts replace if damaged or worn Inspect torch for any cracks or exposed wires replace if necessary Check plasma and secondary supply and pressure flow go m B Purge plasma gas line to remove any m2. 19 Ei6B ps IN 1 i Ne p wr E11 y N use Mes ess TA a e 0 16 al 0 19 10 9 20 E6 5 03441 APPENDIX A 2 Manual 0 2898 APPENDIX 3 MAIN PC BOARD WIRING To Solenoid To Pressure To Temperature Switch Sensor MAIN Pos ASSEMBLY J1 19x1773 J2 RUNSETe SOL 202 1 To Torch Receptacle EX To Current
3. NA Rey IR Fan Panel Fan Shroud HH lt 2 Transformer Bracket NOTE Illustration may vary slightly from unit PARTS LISTS 6 7 Manual 0 2898 6 07 Options and Accessories Oty Description 1 Single Stage Filter Kit Includes Filter And Hose 1 Replacement Filter Body 1 Replacement Filter Element 1 Replacement Filter Hose Not Shown Not shown 1 Multi Purpose Cart Housing Filter Element Cat No 9 7741 Spring O ring y Cat No 9 7743 Assembled Filter Cover Barbed a Fitting d Art 02476 Single Stage Filter Kit PARTS LISTS 68 Catalog 7 7507 9 7740 9 7741 9 7742 7 8888 Manual 0 2898 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 2898 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 PARTS LISTS 6 10 Manual 0 2898 APPENDIX 1 INPUT WIRING REQUIREMENTS pw Power Input Current Input Suggested Sizes See Notes Voies Fea Amps Fuse Amps Wire AWG Wire Canada Won Ph im om 1m 3 6 208 50760 230 50
4. 1 2 8 4 PFC INDUCTOR A INPUT 230V ONLY ARR 5 J7 T1 TEST E11 LEt8 EMC 1 i FILTER CE ONLY 777 E12A D47 O CHASSIS GND E124 r4 K swi H E LEO a Q7 Q8 9 El4A 4 La e 120 208 230V 5 L Te Te INPUT m E16A NN 50 60HZ um IL Mo p F2 E15A swi STUD E13 q Eisa 1 l E12B BIAS E12B CONVERTER E14B AAA Et5B 4 Pe Je Elan S LOGIC AND CONTROL CIRCUITRY art E16B c CURRENT 6 E15B CONTROL a 2 2 O TEST POINTS 3 3 CURRENTADJUST CW E16B O TP1 LOGIC COMMON 20 30 TP2 SHORT TO 23 TO DISABLE BIAS SUPPLY P2 J2 TP6 SHORT TO TP24 TO DISABLE POWER gt SET 81111 PANEL INDICATOR FACTOR CORRECTION sw2 TP8 SHORT TO TP26 TO DISABLE SHORTED RUN TORCH PROTECTION CAUTION SOME PORTIONS OF THE CONTROL LOGIC CIRCUITRY ARE CONNECTED TO THE NORMALLY CLOSED INPUT LINE CONNECTION TO A GROUNDED OVER TEMP INSTRUMENT COULD CAUSE A SHOCK D HAZARD OR DESTROY THE POWER SUPPLY TS1 ACCESS BY AN AUTHORIZED TECHNICIAN ONLY 111 212 10 3 3 L4 MAIN PCB ASSEMBLY x 19X1773 PRESSURE SW E F A 03405 1 2 3 4 APPENDIX A 6 Manual 0 2898
5. 5 6 7 8 9 10 MAIN T3 0 OUTPUT INDUCTOR PRI SEC NT J8 P8 A o E9 L1 E4 E4 E5 E6 E10 E20 E E C C Q13 ds Dser E y 054 _ _ C70 72 81 Q11 7T C71 73 75 D53 8 Eg Q12 x bi 17 T HN 2 a als PILOT d 055 11102 4 4 WORK TORCH i WITCH 2 2143 3 3 9 SWITC 3 3112 2 14VA AGND rene 12VB BGND al 4009 1 4 PIP SZ N7 5 774 QUICK DISCONNECT TORCH SWITCH ON 4 D22 2 P WORK PWM ON 4 99 J1 P1 8011 212 GAS SOLENOID D COMP DESCRIPTION LOCATION TS1 OVER TEMP SENSOR D2 M1 FAN 4 5 12VDC C1 PS1 PRESSURE SWITCH D1 E SOL1 GAS SOLENOID D9 INDUCTOR 4 T3 MAIN TRANSFORMER A7 L1 OUTPUT INDUCTOR A8 swi SWITCH ON OFF B2 sw2 SWITCH RUN SET D1 Rev Revisions By Date e PCB No AA REL ECO 100213 ccu 17 20 02 JHERMAL DYNAMICS THERMAL MATE Assy No AB REL ECO 100333 GCW 10 04 02 KR WEST LEBANON NH 03784 Scale Supersedes AC REL ECO 100535 DAT 2 27 03 A THERMADYNE Company 603 298 5711 F Date een NOTE Drawn References Unless Otherwise Specified Resistors are in Ohms 1 4W 5 GCW Capacitors are in Microfarads UF Chk Sheet 1 of 1 TITLE SCHEMATIC Size DWG No Last Modified Thursday March 20 2003 15 05 29 CM38 120 208 230V SINGLE PHASE 50 60 Hz C 42X1089 5 6 8 9 10 A 03405 Manual 0 2898 A 7 APPENDIX Cover Date 1 31 2003 4 8 2003 7 3 2003 4 12 2006 9 29 0
6. 2 A 5 APPENDIX 6 SYSTEM SCHEMATIC a a 6 APPENDIX 7 PUBLICATION HISTORY iii A 8 Global Customer Service Contact Inside Rear Cover SECTION 1 GENERAL INFORMATION 1 01 Notes Cautions and Warnings Throughout this manual notes cautions and warnings are used to highlight important information These 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 m CAUTION A procedure which if not properly followed may cause damage to the equipment G EEE 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 f
7. LIMITATION OF LIABILITY Thermal shall not under any circumstances be liable for special or consequential damages such as but not limited to damage or loss of purchased or replacement goods or claims of customers of distributor hereinafter Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which such liability is based THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON AUTHORIZED PERSONS The limited warranty periods for Thermal products shall be as follows with the exception of XL Plus Series CutMaster Series Cougar and DRAG GUN A maximum of three 3 years from date of sale to an authorized distributor and a maximum of two 2 years from date of sale by such distributor to the Purchaser and with the further limitations on such two 2 year period see chart below The limited warranty period for XL Plus Series and CutMaster Seri
8. Phosgene a toxic gas is generated from the vapors of chlorinated solvents and cleansers Remove all sources of these vapors This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth de fects and in some cases cancer California Health amp Safety Code Sec 25249 5 et seq Luo 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 D
9. um 5 Disconnectthe input power cable from the switch 6 Connectthe input power cable to the replacement switch with the wires positioned as noted previ ously Vu 7 Transfer wires E1 and E2 to the replacement switch A 03285 8 Attach the replacement Switch to the Power Sup ply front panel Tighten the hardware securely 2 Carefully lift the cover up and away from the unit 9 Connect wires El and E2 to terminals El and E2 to gain access to the ground wire connection on on the PC Board the inside of the cover left side near front 10 Reinstall the Power Supply cover 3 Removethe nutand washer from the ground stud 11 Connectthe PowerSupply to primary input power on the inside of the cover Test the Power Supply for proper operation 4 Installthereplacement cover by reversing the above steps SERVICE 5 2 Manual 0 2898 c WHY yen 1 Replacement Remove the Power Supply cover per Subsection 5 04 A Disconnect the Run Set Switch wire harness from terminal J2 on the PC Board Squeeze together the clips on the rear of the Switch then remove the switch and wire harness through the Front Panel Transfer the wiring harness to the replacement switch Refer to the illustration for wire connec tions 5 gt Top clip M Wire 8 Wire 9 A 03493 Pass the wiring harness through the front opening in the Power Supply Press the switch into posi tion in the Powe
10. Connect the volt ohmmeter positive lead to the an ode of the diode and the negative lead to the cath ode of the diode for forward bias testing refer to following figure A properly functioning diode will conduct in the forward bias direction and indicate be tween 0 3 to 0 9 volts Art A 00307 0 75 Forward Bias Diode Conducting De Diode Test Symbol VR COM A Anode 19 Cathode Testing Diode Forward Bias TROUBLESHOOTING 48 Reverse the meter leads across the diode for reverse bias testing refer to following figure A properly functioning diode will block in the reverse bias direc tion and depending on the meter function will indi cate an open or OL Art A 00306 OL Reverse Bias Diode Not Conducting I VR COM Z Cathode UP Anode Testing Diode Reverse Bias Manual 0 2898 D Diode Bridge Checks Check for shorted Diode Bridges A 03508 Disconnect primary input power With an ohmmeter set on the diode range make the following checks on both diode bridges The meter should indicate a diode drop in one direction and an open in the other direction for each check Manual 0 2898 4 9 TROUBLESHOOTING TROUBLESHOOTING 4 10 Manual 0 2898 SECTION 5 SERVICE 5 01 Introduction This section describes parts replac
11. crans de protection Utilisez la nuance de lentille qui est sugg r e dans le recommendation qui suivent ANSI 5 Z49 1 Nuance Minimum Nuance Sugger e Courant Arc Protective Num ro Num ro Moins de 300 8 9 300 400 9 12 400 800 10 14 Ces valeurs s appliquent ou l arc actuel est observ clairement L experience a d montrer que les filtres moins fonc s peuvent utilis s quand l arc est cach par moiceau de travail Ol 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 ou e contre les bruits forts portez des tampons protecteurs et ou des protections auriculaires Prot gez galement les autres personnes se trouvant sur le lieu de travail 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 2898 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 disponibl
12. or even complete torch failure Contaminants may cause poor cutting performance and rapid electrode wear Optional filters provide increased filtering capabilities Manual 0 2899 3 1 DESCRIPTION DESCRIPTION 3 2 Manual 0 2898 SECTION 4 TROUBLESHOOTING 4 01 Introduction This section provides service diagnostics for the CutMas ter 38 Power Supply allowing the Technician to isolate any faulty subassemblies 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 This manual covers the Power Supply only Troubleshooting other parts of the system is cov ered in separate manuals for those products 4 02 Periodic Inspection amp Cleaning Procedures This subsection describes inspection procedures which should be performed at periodic intervals as required A Physical Inspection Check that all wiring connections are secure B Cleaning Open the enclosure and use a vacuum cleaner to re move any accumulated dirt and dust The unit should also be wiped clean If necessary solvents for clean ing electrical apparatus may be used Refer to Appendix for maintenance schedule and pro cedures Clean or replace filters per Section 5 07 4 03 System Design The CutMaster 38 System is designed for hand cutting only Manual 0 2898 4 04 Common Operating Problems GS Disconnect
13. Cable with plug for non CE units through Unit Rev AE Input Power Cable with plug for non CE units at Unit Rev AF or later Input Power Cable for CE units Rev AA AB Input Power Cable for CE units Rev AC or later Input Power Cable for CE Australian units Power CableStrain Relief for non CE units through Unit Rev AE Power Cable Strain Relief for non CE units at Unit Rev AF or later Power Cable Strain Relief for CE units Rev AA AB Power Cable Strain Relief for CE units Rev AC or later Power Cable Strain Relief for CE Australian units Catalog 9 8630 7 3345 9 4466 9 8628 9 8660 9 8661 9 8671 9 8663 8 4263 8 7072 8 7072 9 8672 8 4250 Manual 0 2898 A 03498 Input Filter amp Bracket CE Units only NOTE Illustration may vary slightly from unit Manual 0 2898 6 5 PARTS LISTS 6 06 Right Side Replacement Parts Item Qty 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8A 8B 1 9 1 10 1 PARTS LISTS Description Console ATC Assembly Regulator Filter Assembly includes Pressure Switch Pressure Gauge Solenoid Pressure Gauge Pressure Switch Regulator Filter Replacement Element Regulator Mounting Nut Assembly Output Inductor PFC Choke Type 8B assembly replaces Type 8A Main Transformer Assembly Fan Ref PS1 L1 T1 T3 1 Catalog 9 8641 9 8643 9 1045 9 1044 9 4414 9 5804 9 8626 9 8627 9 8625 9 8639 Manual 0 2898
14. above 65 psi 4 5 bar and there is continuity between sockets 2 and 3 replace PC board 4 08 Pilot Arc Problems Locate your symptom below A No pilot arc Gas flows continuously AC indica tor ON TEMP indicator OFF GAS indicator ON DC indicator OFF 1 Shorted Torch a Test torch and leads for continuity 2 Faulty PC Board a Replace PC Board TROUBLESHOOTING B No arc or intermittent arc in torch Gas flows AC indicator ON TEMP indicator OFF GAS and DC indicators ON 1 Gas pressure set incorrectly too high a Setgas pressure on the Power Supply gas regu lator to 65 psi 4 5 bar 2 Oil moisture in air lines a Purge system If problem is corrected add fil ters in line with air source 3 Torch consumable parts incorrect or worn a Refer to Operator s Manual 4 Starter cartridge missing from torch a Shut off power Remove shield cup from torch Install starter cartridge if missing Faulty leads a Check continuity 6 Faulty torch a Check continuity 7 Faulty PC Board a Replace PC Board No pilot arc GAS and DC indicators blink 1 Gas pressure is too low a Set gas pressure to 65 psi 4 5 bar D No gas flow AC and GAS indicators ON TEMP 46 and DC indicators OFF 1 Upper O ring on torch head is in wrong position a Remove shield cup from torch check position of upper O ring Correct if necessary Art A 03640 Upper Groove with Vent Holes Must
15. antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre s l nium b ryllium mangan se vanadium Lisez toujours les fiches de donn es sur la s curit des mati res sigle am ricain MSDS celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS contiennent des renseignements quant la quantit et la nature de la fum e et des gaz pouvant poser des dangers de sant e Pour des informations sur la mani re de tester la fum e et les gaz de votre lieu de travail consultez l article 1 et les documents cit s la page 5 Utilisez un quipement sp cial tel que des tables de coupe d bit d eau ou courant descendant pour capter la fum e et les gaz N utilisez pasle chalumeau au jet de plasma dans une zone se trouvent des mati res ou des gaz combus tibles ou explosifs Lephosgene 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
16. developing technologically advanced products to achieve a safer working environment within the welding industry 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 System CutMaster 38 Power Supply Model SL60 Air Plasma Cutting Torch Operating Manual Number 0 2898 Published by Thermal Dynamics Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermal dynamics com Copyright 2002 2003 2004 2005 2006 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 September 29 2004 Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial Torch Serial SECTION 1 TABLE OF CONTENTS GENERAL INFORMATION 100 1 1 1 01 Notes Cautions an
17. lectrique haute tension Cette nergie lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres personnes sur le lieu de travail GENERAL INFORMATION 14 e Netouchez jamais une pi ce sous tension ou vive portez des gants et des v tements secs Isolez vous de la piece de 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 A o ET EXPLOSION Les incendies et les explosions peuvent r sulter des scories chaudes des tincelles ou de l arc de plasma Le proc d l arc de plasma produit du m tal des tincelles des scories chaudes pouvant mettre le feu aux mati res com bustibles ou provoquer l explosion de fum es inflammables e Soyez certain qu aucune mati re combustible ou in flammable se trouve sur le lieu de travail Prot gez toute telle mati re qu il est impossible de retirer de la zone de travail Procurez une bonne a ration de toutes les fum es inflammables ou explosives Necoupez pas et ne soudez pas les conteneurs ayant pu re
18. magn tique qui peuvent interf rer la fonction propre d un pacemaker cardiaque les appareils auditif ou autre mat riel de sant electronique Ceux qui travail pres d une application l arc au jet de plasma devrait consulter leur membre professionel de m dication et le manufacturier de mat riel de sant pour d terminer s il existe des risques de sant Il faut communiquer aux op rateurs et au person nel TOUS les dangers possibles Afin d viter les blessures possibles lisez comprenez et suivez tous les avertissements toutes les pr cautions de s curit et toutes les consignes avant d utiliser le mat riel Composez le 603 298 5711 ou votre distributeur local si vous avez des questions NENNEN Au etGAZ sante 1 3 La fum e et les gaz produits par le proc d de jet de plasma peuvent pr senter des risques et des dangers de GENERAL INFORMATION e 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
19. plasma gas stream swirls as it leaves the torch The purpose of the swirl is to maintain a smooth col umn of gas The swirl effect results in one side of a cut being more square than the other Viewed along the direction of travel the right side of the cutis more square than the left 4 1 TROUBLESHOOTING E Dross When dross is present on carbon steel it is commonly referred to as either high speed slow speed or top dross Dross present on top of the plate is normally caused by too great a torch to plate distance dross is normally very easy to remove and can often be wiped off with a welding glove Slow speed dross is normally present on the bottom edge of the plate It can vary from a light to heavy bead but does not adhere tightly to the cut edge and can be scraped off easily High speed dross usually forms a narrow bead along the bottom of the cut edge and is very difficult to remove When cutting a troublesome steel it is sometimes useful to reduce the cutting speed to pro duce slow speed dross Any resultant cleanup can be accomplished by scraping not grinding F Common Cutting Faults 1 Insufficient Penetration a Cutting speed too fast b Torch tilted too much c Metal too thick d Worn torch parts e Cutting current too low f Non Genuine Thermal Dynamics parts used 2 Main Arc Extinguishes a Cutting speed too slow b Torch standoff too high from workpiece c Cutting current too high
20. primary power at the source before dis assembling the power supply torch or torch leads Frequently review the Important Safety Precau tions in Section 1 of this manual Be sure the op erator is equipped with proper gloves clothing and eye and ear protection Make sure no part of the operator s body comes into contact with the work piece 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 ET A Piloting Piloting is harder on parts life than actual cutting be cause the pilot arc is directed from the electrode to the tip rather than to a workpiece Whenever pos sible avoid excessive pilot arc time to improve parts life Torch Standoff Improper standoff the distance between the torch tip and workpiece can adversely affect tip life as well as shield cup life Standoff may also significantly affect the bevel angle Reducing standoff generally results in a more square cut Edge Starting For edge starts hold the torch perpendicular to the workpiece with the front of the torch tip at the edge ofthe workpiece not touching at the point where the cut is to start When starting at the edge of the plate do not pause at the edge and force the arc to reach for the edge of the metal Establish the cutting arc as quickly as possible Direction of Cut The
21. problems Do not forget about these cables when troubleshooting While troubleshooting visually inspect the inter nal components for signs of overheating fractures and damage Manual 0 2898 4 06 Circuit Fault Isolation This section is to help isolate the defective circuit before troubleshooting identify symptoms and test the unit for proper operation Follow the instructions as given to 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 A Initial Setup Conditions 1 Connect gas supply to rear of Power Supply 2 Turn on gas supply and adjust Power Supply Gas Regulator to 65 psi 4 5 bar 3 Setthe Power Supply controls as follows ON OFF O switch to OFF O CURRENT control knob to maximum RUN SET switch to SET Main Input and Internal Power Tests 1 Connect main AC power to the unit 2 Set the Power Supply ON OFF switch to ON up position and check the following AC indicator steady ON TEMP Indicator OFF e GAS Indicator N ON Gas flows from torch Fan operates DC Indicator is OFF 3 Turn RUN SET switch to RUN Gas should stop flowing 4 Turn ON OFF switch to OFF then back to ON Check the following AC indicator ON Temp indicator OFF Gas indicator ON gas does not flow Fan Operates e DC indicator OFF This complete
22. selec tion of standard options and Accessories are to be made to this equipment C Customer Operator Responsibilities It is the customer operator s responsibility to maintain the equipment and peripheral accessories provided by Thermal Dynamics in good operating order in accordance with the procedures outlined in the operating manual and to protect the equipment from accidental or mali cious damage D Repair Restrictions The electronics consists of a Printed Circuit Board PCB Assembly which must be carefully handled and must be replaced asa unit No replacement of individual printed circuit components is allowed except as noted in this manual Printed Circuit Board Assemblies to be returned must be properly packaged in protective material and returned intact per normal procedures Manual 0 2898 2 03 Service Responsibilities The service technician should be familiar with the equip ment and its capabilities and should be prepared to rec ommend arrangements of components which will pro vide the most efficient layout utilizing the equipment to its best possible advantage Maintenance work should be accomplished in a timely manner If problems are encountered or the equip ment does not function as specified contact the Tech nical Services Department at West Lebanon NH for assistance 1 603 298 5711 2 1 INTRODUCTION INTRODUCTION 2 2 Manual 0 2898 SECTION 3 DESCRIPTION 3 01 Scope The purpose of this
23. 6 AA AA 01 APPENDIX 7 PUBLICATION HISTORY Details Manual Released Revised updated trouble shooting per Tech Service updated system schematic to Rev AC added CE input filter Updated power cord per ECO 100487 added pin out diagram for torch connector Added input power cords amp strain reliefs per ECOs 101877 amp B049 Added patent information at the end of section 6 per ECO B193 Updated rear cover adding contact information Applied next rev level fomat IHERMAL DYNAMICS Thermadyne USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Email sales thermadyne com Thermadyne Victor Brasil Avenida Brasil 13629 Cordovil Rio de Janeiro Brazil 21012 351 Telephone 55 21 2485 8998 Fax 55 21 2 485 8735 Thermadyne Canada 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Thermadyne Chile Piloto Lazo 90 Cerrillos Santiago Chile 7278 654 Telephone 56 2 557 2465 Fax 56 2 557 5349 Thermadyne Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Global Customer Service Contact Information Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial
24. 760 Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electric Code NOTES Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements Cable size is de rated based on the Duty Cycle of the equipment The suggested sizes are based on flexible power cable with power plug installations For hard wired installations refer to local or national codes Cable conductor temperature used is 167 F 75 C An energy limiting fuse UL Class RK 1 examples BUSS LPS LPN RK or Gould Shawmut AZK A6K should be used to minimize damage to Plasma Cutting Welding or power distribution equipment NEVER use replaceable element fuses like UL Class H or one time fuses like UL Class K5 Manual 0 2898 1 APPENDIX APPENDIX 2 MAIN POWER PC BOARD LAYOUT J2 J D99 J7 J9 X MAIN PCB ASSEMBLY J2 Jt 19 1773 REV T J7 AUNSET e SOL 1 1 DEC NUES Kor 829 he a
25. AZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCI S disponible aupr s de la Na tional Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 GENERAL INFORMATION 9 Norme 70 de la NFPA CODE ELECTRIQUE NA TIONAL disponible aupr s dela National Fire Pro tection Association Batterymarch Park Quincy MA 02269 10 Norme 51B de la NFPA LES PROC D S DE COUPE ET DE SOUDAGE disponible aupres de la National Fire Protection Association Batterymarch Park Quincy MA 02269 11 Brochure GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIM S EN CYLINDRES disponible aupres de l Association des Gaz Comprim s Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 Norme CSA W117 2 CODE DE S CURIT POUR LE SOUDAGE ET LA COUPE disponible aupres de l Association des Normes Canadiennes Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 Livret NWSA BIBLIOGRAPHIE SUR LA S CURIT DU SOUDAGE disponible aupres de l Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 14 Norme AWSFA 1 de l Association Am ricaine de Soudage RECOMMANDATIONS DE PRATIQUES SURES POUR LA PREPARATION 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
26. IHERMAL Dynamics 6 CUTMASTER PLASMA CUTTING SYSTEM IHERMAL Dynamics WE APPRECIATE YOUR BUSINESS Congratulations on your new Thermal Dynamics product We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry This product is backed by our extensive warranty and world wide service network To locate your nearest distributor or service agency call 1 800 426 1888 or visit us on the web at www thermal dynamics com This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product Your satisfaction with this product and its safe operation is our ultimate concern Therefore please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermadyne Industries Inc We distinguish ourselves from our competition through market leading dependable products that have stood the test of time We pride ourselves on technical innovation competitive prices excellent delivery superior customer service and technical support together with excellence in sales and marketing expertise Above all we are committed to
27. ION 5 SERBVIGE ner ertt e m tit ua otv 5 1 5 01 Introduction tete et eate i 5 1 5 02 Anti Static Handling Procedures ssssssseeseneeneeenn nnns 5 1 5 03 Parts Replacement General Information 5 1 5 04 Major External Parts Replacement 5 2 5 05 Front Panel Parts 2 4 5 2 5 06 Left Side Internal Parts Replacement 5 8 5 07 Rear Panel Parts 5 4 5 08 Right Side Internal Parts Replacement 5 5 TABLE OF CONTENTS continued SECTION 6 PARTS LISTS anne es IH eek ia d qb ed ee 6 1 6 01 Introduction reo eere toe ieri rene ee N Elan 6 1 6 02 Ordering Information su 6 1 6 03 Major External Replacement Parts 2 6 2 6 04 Front Panel Replacement Parts 6 3 6 05 Left Side Replacement Parts 800 6 4 6 06 Right Side Replacement Parts 2 6 6 6 07 Options and Accessories ssssssssssssseeeeeeenneneee nennen 6 8 PATENT INFORMATION et aea teme ecu pee Hr ed teta eee tage 6 9 APPENDIX 1 INPUT WIRING REQUIREMENTS iii A 1 APPENDIX 2 MAIN POWER PC BOARD A 2 APPENDIX 3 MAIN PC BOARD WIRING ici A 3 APPENDIX 4 MAINTENANCE SCHEDULE iii A 4 APPENDIX 5 TORCH CONNECTOR
28. Miami FL 33126 15 Norme ANSI Z88 2 PRATIQUES DE PROTECTION RESPIRATOIRE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 GENERAL INFORMATION 1 6 Manual 0 2898 1 07 Declaration of Conformity Manufacturer Thermal Dynamics Corporation Address 82 Benning Street West Lebanon New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive European Council Directive 73 23 EEC as amended by Council Directive 93 68 EEC and to the National legislation for the enforcement of this Directive 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 ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting equipment and associ ated accessories Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac turing process This is to ensure the product is safe when used
29. 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 S Giuliano Milan Italy Tel 39 02 98 80320 Fax 39 02 98 281773 Thermadyne South Africa 209 Risi Ave Linmeyer Johannesberg 2197 South Africa Tel 27 11 917 3600 Fax 27 11 917 8580 Thermadyne International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 Suite 300 St Louis MO 63017 Telephone 636 728 3000 Email TDCSales Thermadyne com www thermadyne com 16082 Swing Ridge Roa IHERMAL DYNAMICS
30. Remain Open Upper O Ring 2 Correct Groove WO Lower O Ring a Manual 0 2898 4 09 Main Arc Problems Locate your symptom below A Main cutting arc will not start 1 Work cable not connected a Connect work cable 2 Holding too high of a standoff a Refer to Operating Manual for recommended standoff heights 3 Workpiece is painted or rusty a Clean workpiece 4 Starter cartridge missing from torch a Shutoff power Remove shield cup from torch Install starter cartridge if missing 5 Faulty Main Power PC Board a Replace PC Board 4 10 Test Procedures The test procedures in this subsection are referenced in the troubleshooting section A Safety Precautions 1 Significant DC Voltage exists after removal of input power Allow two minutes for discharge time Volt age measured on input capacitors must be zero be fore performing service on the power supply Do Not touch electrical components with any part of the human body when power is applied Keep away from any moving parts Hot surfaces can cause severe burns Allow equip ment to cool before servicing Electrostatic discharge can damage printed circuit board assemblies Transport printed circuit boards in proper antistatic shielded packages Use proper grounding techniques with wrist strap before handling printed circuit boards Misaligned plugs can cause printed circuit board dam age Be sure plugs are properly aligned
31. Standard AWSF4 1 RECOM MENDED SAFE PRACTICES FOR THE PREPARA TION FOR WELDING AND CUTTING OF CONTAIN ERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 ANSI Standard Z88 2 PRACTICE FOR RESPIRATORY PROTECTION obtainable from American National Standards Institute 1430 Broadway New York 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 systeme Manual 0 2898 m ATTENTION Toute proc dure pouvant r sulter l endommagement du mat riel en cas de non respect de la proc dure en question SSEMENT Toute proc dure pouvant provoquer des blessures de l op rateur ou des autres personnes se trouvant dans la zone de travail en cas de non respect de la proc dure en question 1 05 Precautions De Securite Importantes SSEMENTS L OP RATION ET LA MAINTENANCE DU MAT RIEL DE SOUDAGE L ARC AU JET DE PLASMA PEUVENT PR SENTER DES RISQUES ET DES DANGERS DE SANT Coupant l arc au jet de plasma produit de l nergie lectrique haute tension et des missions
32. according to instructions in this manual and related industry standards and performs as specified Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications Thermal Dynamics has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative Giorgio Bassi Managing Director Thermal Dynamics Europe Via rio Fabbiani 8A 40067 Rastignano BO Italy Manual 0 2898 1 7 GENERAL INFORMATION 1 08 Statement of Warranty LIMITED WARRANTY Thermal Dynamics Corporation hereinafter Thermal warrants that its products will be free of defects in workmanship or material Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below Thermal shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal s specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at Thermal s sole option of any components or parts of the product determined by Thermal to be defective THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
33. al Standards Institute 1430 Broadway New York NY 10018 Manual 0 2898 10 1 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 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
34. and com pletely seated Excessive pressure can damage printed circuit board Use only minimal pressure and gentle movement when disconnecting or connecting printed circuit board plugs Manual 0 2898 B Opening Power Supply Enclosure The cover of the Power Supply must be removed to gain access to the input power connections Disconnect primary power at the source before as sembling or disassembling the Power Supply torch parts or torch and leads assemblies Remove the upper screws securing the cover to the main assembly 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 Carefully lift the cover off the unit and remove the nut securing the ground wire to the side panel Reinstall the cover by reversing the above steps A 03285 TROUBLESHOOTING C Diode Testing Basics Testing of diode modules requires a digital volt ohm meter that has a diode test scale Remember that even if the diode module checks good it may still be bad If in doubt replace the diode module 1 2 Locate the diode module to be tested Remove cables from mounting studs on diodes to iso late the module Set digital volt ohmmeter to diode test scale Using the Figures for each test check each diode in the module Each diode must be checked in forward bias plus to negative and reverse bias negative to plus direction
35. any part of the Power Supply first read the procedure for the part to be replaced then pro ceed with the disassembly 5 1 SERVICE 5 04 Major External Parts 5 05 Front Panel Parts Replacement Replacement Refer to Section 6 for Front Panel Replacement Parts and Refer to Section 6 for Major External Replacement Parts overall detailed drawing and overall detailed drawing Li G A G Disconnect primary power from the source before Disconnect primary power from the source before opening or disassembling the power supply opening or disassembling the power supply A Output Control A Knob Replacement A Cover Removal and Replacement 1 Turn the adjustment knob fully clockwise and note 1 Remove the upper screws securing the cover to the unit then loosen the lower screws securing the 2 Loosen the screw securing the Knob to the poten cover to the base tiometer shaft and remove the Knob 3 Place the replacement Knob on the potentiometer shaft with the location of the pointer the same as noted in step 1 4 Tighten the screw to secure the knob to the poten tiometer shaft B ON OFF O Switch Replacement 1 Remove the cover per Subsection 5 04 A 2 Disconnect wires El and E2 leading from the switch to terminals El and E2 on the PC Board 3 Remove the hardware securing the switch to the Power Supply front panel 4 Note the positions of the wires from the input power cable to the switch
36. body by compressing the spring on the spool Tighten firmly by hand Reinstall the bowl Connect the drain tube to the bowl Reinstall Power Supply cover per Section 5 04A Turn on the air supply Test the Power Supply for proper operation SERVICE B Pressure Switch Replacement 1 2 Remove the cover per Subsection 5 04 A Label and disconnect the wires to the Pressure Switch Turn the Pressure Switch to remove it from the Regulator Filter Assembly Apply thread sealant to the threads of the replace ment Pressure Switch NOTE Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small gas passages in the torch Thread the replacement Pressure Switch into place on the Regulator Filter Assembly Tighten se curely Connect the wires from the Pressure Switch wire harness with the wires positioned as marked pre viously Reinstall the Power Supply cover Reconnect the gas supply and primary input power Test the Power Supply for proper opera tion SERVICE 5 6 Manual 0 2898 SECTION 6 PARTS LISTS 6 01 Introduction A Parts List Breakdown The parts lists provide a breakdown of all replaceable components The parts lists are arranged as follows Section 6 03 Major External Replacement Parts Section 6 04 Front Panel Replacement Parts Section 6 05 Left Side Replacement Parts Section 6 06 Right Side Replacement Parts Section 6 07 Options and Ac
37. cessories NOTE Parts listed without item numbers are not shown but may be ordered by the catalog number shown B Returns If a product must be returned for service contact your distributor Materials returned without proper authori zation will not be accepted 6 02 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 autho rized distributor Manual 0 2898 6 1 PARTS LISTS 6 03 Major External Replacement Parts Item Qty Description Catalog 1 1 Cover with labels 9 8631 1 Base Enclosure Assembly 9 8640 3 1 Tube rollhandle 9 8632 A 03433 NOTE Illustration may vary slightly from unit PARTS LISTS 6 2 Manual 0 2898 6 04 Front Panel Replacement Parts Item Qty Description Ref Catalog 1 1 On Off Switch Sw1 8 4248 2 1 Output Current Control Potentiometer with wire harness 9 8629 3 1 Run Set Switch SW2 9 1042 4 1 Output Current Control Knob 9 8527 5 1 Work Cable with Clamp 20 Ft 6 1 m 9 8642 2 A 03496 NOTE Illustration may vary slightly from unit Manual 0 2898 6 3 PARTS LISTS 6 05 Left Side Replacement Parts Item Qty 1 1 2 1 3 1 4 1 4 1 4 1 4 1 4 1 NotShown 1 1 1 1 1 PARTS LISTS Description Ref PCB Assembly Diode Bridge BR1 BR2 Thermal Pad Input Power
38. d Work cable disconnected e Worn torch parts f Non Genuine Thermal Dynamics parts used 3 Excessive Dross Formation a Cutting speed too slow b Torch standoff too high from workpiece c Worn torch parts d Improper cutting current e Non Genuine Thermal Dynamics parts used TROUBLESHOOTING 4 2 4 Short Torch Parts Life a Moisture in air source b Exceeding system capability material too thick c Excessive pilot arc time d Gas pressure too low e Improperly assembled torch f Incorrect torch parts for the operation 9 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 A General Information The CutMaster 38 Operating Manual describes basic troubleshooting and parts replacement procedures This Service Manual covers advanced troubleshooting which requires power supply disassembly and live mea surements Advanced troubleshooting and repair of this unit should be undertaken only by those familiar with high voltage high power electronic equipment If major complex subassemblies are faulty the faulty sub assembly must be returned for repair NOTE Follow all instructions as listed and complete each in the order presented The troubleshoo
39. d Warnings 1 1 1 02 Important Safety Precautions 1 1 1 03 Publications PORE pt ea 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 Conformity 1 7 1 08 Statement of Warranty 2 1 8 SECTION 2 INTRODUCTION ro rhum irent 2 1 2 01 Scope Of Manual tied ina 2 1 2 02 General Service Philosophy ss 2 1 2 03 Service Responsibilities 0 2 1 SECTION 3 DESCRIPTION A AN e S ELO toL DV UE E ea ur 3 1 SO 4SCOD6 oo Eee DEN EAT Soe 3 1 3 02 Specifications Design Features 3 1 SECTION 4 TROUBLESHOOTING enr t e t Rea epe eden etas 4 1 4 01 Introduction ene Pt e eR E RR 4 1 4 02 Periodic Inspection amp Cleaning 4 1 4 03 System DeSIQN it eee eed eld dt n dd 4 1 4 05 Troubleshooting Guide General Information 4 2 4 06 Circuit Fault Isolation 4 3 4 07 Main Input and Internal Power 4 4 4 08 Pilot Arc Problems ss 4 6 4 09 Main Arc Problems eid nalen a ie 4 7 4 10 Test 4 4 7 SECT
40. e 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 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 7411 NORMES POUR LES CHAUSSURES PROTECTRICES disponible aupres 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 de 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 G
41. ement procedures and all repairs which may be performed on the CutMaster 38 Power Supply Replacement instructions not included in this manual are supplied with the replacement kit Under no circumstances are field repairs to be attempted on Printed Circuits or other subassemblies of this unit Evidence of unauthorized repairs may void the factory warranty 5 02 Anti Static Handling Procedures A General Caution PC Boards can be irreparably damaged by im proper handling due to electrostatic discharge ESD Replacement PC Boards are shipped in a protective en closure to prevent damage from electrostatic discharge ESD during shipping Included with each replacement board is a ground strap to prevent static damage during installation GS Read and understand these instructions and the instructions on the grounding wrist strap package before opening the equipment enclosure or remov ing the replacement PC board from its protective enclosure Disconnect primary power to the system before dis assembling the torch torch leads or power supply enclosure Do not operate the equipment or test equipment under power while wearing the grounding wrist strap Observe torquing requirements where given Fail ure to torque properly will cause component dam age Manual 0 2898 B Procedure 1 Openthe wriststrap and unwrap the first two folds of the band Wrap the adhesive side firmly around your wrist 2 Unrollt
42. es shall be as follows A maximum of four 4 years from date of sale to an authorized distributor and a maximum of three 3 years from date of sale by such distributor to the Purchaser and with the further limitations on such three 3 year period see chart below The limited warranty period for Cougar and DRAG GUN shall be as follows A maximum of two 2 years from date of sale to an authorized distributor and a maximum of one 1 year from date of sale by such distributor to the Purchaser and with the further limitations on such two 2 year period see chart below Parts XL Plus amp Parts Parts PAK Units Power Supplies CutMaster Series Cougar Drag Gun Others Labor Main Power Magnetics 3 Years 1 Year 2 Years 1 Year Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year Control PC Board 3 Years 1 Year 2 Years 1 Year All Other Circuits And Components Including 1 Year 1 Year 1 Year 1 Year But Not Limited To Starting Circuit Contactors Relays Solenoids Pumps Power Switching Semi Conductors Consoles Control Equipment Heat 1 Year 1 Year 1 Year Exchanges And Accessory Equipment Torch And Leads Maximizer 300 Torch 1 Year 1 Year SureLok Torches 1 Year 1 Year 1 Year All Other Torches 180 Days 180 Days 180 Days 180 Days Repair Replacement Parts 90 Days 90 Days 90 Days None Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics repair facility wit
43. he rest of the band and peel the liner from the copper foil at the opposite end 3 Attachthe copper foil to a convenient and exposed electrical ground Connect the equipment primary cable ground to the same electrical ground as the wrist strap 5 Open the equipment enclosure and remove the failed PC board 6 Carefully open the ESD protective bag and remove the replacement PC Board 7 Install the replacement PC Board in the equipment and make all necessary connections 8 Place the failed PC Board in the ESD protective bag and seal for return shipping 9 Replace the power supply cover 10 Remove the grounding wrist strap from your wrist and from the electrical ground connection before reconnecting primary power to the equipment 5 03 Parts Replacement General Information The parts replacement procedures described in this manual require that the Power Supply be opened and partially disassembled The part to be replaced will de termine the extent of disassembly Before removing any connection mark each wire with the connection designation When reassembling make sure the wires go to the proper terminals Note the routing of wires and make sure the wires are put back in the same place when re assembling the unit Refer to Section 6 for parts lists and overall detailed draw ings A G Disconnect the power supply from input power be fore opening or disassembling the power supply Before disassembling
44. hin thirty 30 days of the repair No transportation costs of any kind will be paid under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer All returned goods shall be at the customer s risk and expense This warranty supersedes all previous Thermal warranties Effective November 15 2001 GENERAL INFORMATION 1 8 Manual 0 2898 SECTION 2 INTRODUCTION 2 01 Scope Of Manual This manual provides service instructions for the Ther mal Dynamics CutMaster 38 Plasma Cutting Power Sup ply Information in this manual 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 2888 Read both the operating manual and the service manual thoroughly A complete understanding of the capabili ties and functions of this equipment will assure obtain ing the performance for which it was designed 2 02 General Service Philosophy Several key points are essential to properly support the application and operation of this equipment A Application The equipment should satisfy the customer s require ments as supplied and as described in Section 3 of this manual Be sure to confirm that the equipment is capable of the application desired B Modifications No physical or electrical modifications other than
45. ing Layout Check the input power cable for proper connections Reconnect if necessary b Test input power cable for continuity through all conductors Replace cable if any conductor does not show continuity B Main power line fuses blow immediately after the ON OFF Switch is turned on 1 Faulty input diode bridge s a Testinput diode bridges per section 4 10 D re place as needed TROUBLESHOOTING 4 4 Fan does operate AC indicator is OFF 1 Front Panel ON OFF switch in OFF down position a Place switch to ON up position 2 Main power disconnect open OFF a Close main power disconnect 3 Main power line fuses blown a Replace main power line fuses 4 Input power cable disconnected or faulty a Check power cable for proper connections to On Off Switch b Check power cable for continuity through all conductors 5 Wires from On Off Switch to PC Board disconnected or faulty a Check for proper connections b Disconnect wires check for continuity 6 Faulty ON OFF switch a Disconnect primary input power Set the On Off switch to ON UP position Test for conti nuity between terminals 1 and 2 and between terminals 3 and 4 If there is no continuity re place the ON OFF Switch A 03500 Terminal 2 To PC Board Terminal E2 Terminal 1 Input Power Cord Line 2 Input Power Cord Line 1 7 Faulty Bias Transformer a Refer to PC Board Wir
46. ing Layout in the Appen dix Test for 380 410 vdc between TP 21 and TP 101 on PC Board If voltage is not correct replace the PC Board Manual 0 2898 D AC indicator flashing TEMP indicator OFF on system start up RUN SET switch in RUN position 1 Torch shield cup loose a Shut power supply off Tighten shield cup se curely Turn unit back on 2 Torch connection at power supply loose a Shut power supply off Tighten torch leads male connector into female receptacle on power supply securely Turn power supply back on 3 Faulty PIP switch or open PIP wires in torch leads a Check torch PIP switch for continuity b Check torch PIP leads for continuity 4 J3 wire connector disconnected from PC board a Check J3 connector reconnect if necessary E Gas flows continuously AC indicator ON TEMP indicator OFF DC indicator OFF GAS indicator ON 1 RUN SET Switch in SET down position a Change to RUN up position 2 Faulty RUN SET switch a Disconnect primary input power Disconnect wires from RUN SET switch Put switch in RUN up position Check switch for open con dition If switch is shorted replace switch E AC indicator flashing on start up TEMP indicator OFF RUN SET switch in RUN posi tion gas flows from torch 1 Torch switch stuck ON or torch switch wires shorted a Check indicator D22 on PC board Indicator should be OFF unless torch switch is closed b Check torch switch for
47. ly Position the Regulator Filter Assembly in the bracket at the top of the Power Supply Secure with the locking ring Connect the gas tube to the Pressure Switch As sembly Adapter Fitting Push in the Fitting and insert the gas tube Release the Fitting The fitting will automatically lock Check for a secure con nection Position the bottom end of the drain tube in the hole in the Power Supply base Reinstall the Power Supply cover Connect the gas inputline to the inlet port Connect the Power Sup ply to primary input power Test the Power Supply for proper operation C Optional Single Stage Filter Element Replacement 1 2 54 NOTES The Power Supply shuts down automatically when the Filter Element becomes completely saturated The Filter Element can be removed from its hous ing dried and reused Allow 24 hours for Ele ment to dry Remove power from power supply Disconnect gas supply hose Housing Filter Element Cat No 9 7741 O ring Cat No 9 2743 Assembled Filter Cover Barbed 2 Fitting Art 02476 Manual 0 2898 Turn the Cover counter clockwise and remove it from the Filter Housing The Filter Element is lo cated inside the Housing Remove the Filter Element from the Housing and set Element aside to dry Wipe inside of housing clean then insert the re placement Filter Element open side first as shown Replace Housing on Cover Attach gas supp
48. ly hose NOTE If unit leaks between housing and cover inspect the O Ring for cuts or other damage 5 08 Right Side Internal Parts Replacement Refer to Section 6 for Right Side Internal Parts List and overall detailed drawing G Disconnect input power at the source and bleed down the system before attempting these proce dures A Standard Filter Element Replacement 1 2 Remove Power Supply Cover per Section 5 04A Remove power from the power supply turn off the gas supply Remove the drain tube from the bottom of thebowl on the Regulator Filter Assembly Manual 0 2898 5 5 10 I Ring i Replacement Element No 9 4414 Bowl Drain Tube Unscrew the bowl on the bottom of the Regula tor Filter Assembly The filter element will be visible and still attached to the main body of the Regulator Filter Assembly Grasp the filter element and unscrew it from the Regulator Filter body The filter element will come off with a spool and some additional pieces Note the correct assembly of the filter spool then remove the filter from the spool Either clean or replace the filter element The filter element and spool with the baffle ring in place teeth facing downward can be screwed back into the Regulator
49. nfermer des mati res combustibles e Pr voyez une veille d incendie lors de tout travail dans une zone pr sentant des dangers d incendie Le gas hydrog ne peut se former ou s accumuler sous les pi ces de travail en aluminium lorsqu elles sont coup es sous l eau ou sur une table d eau NE PAS couper les alliages en aluminium sous l eau ou sur une table d eau moins que le gas hydrog ne peut s chapper ou se dissiper Le gas hydrog ne accumul explosera si enflamm m RAYONS D ARC DE PLASMA Les rayons provenant de l arc de plasma peuvent blesser vos yeux et br ler votre peau Le proc d l arc de plasma produit une lumi re infra rouge et des rayons Manual 0 2898 ultra violets tr s forts Ces rayons d arc nuiront vos yeux et br leront votre peau si vous ne vous prot gez pas correctement Pourprot ger vos yeux portez toujours un casque ou un cran de soudeur Portez toujours des lunettes de s curit munies de parois lat rales ou des lunettes de protection ou une autre sorte de protection oculaire e Portez des gants de soudeur et un v tement protecteur appropri pour prot ger votre peau contre les tincelles et les rayons de l arc Maintenez votre casque et vos lunettes de protection en bon tat Remplacez toute lentille sale ou comportant fissure ou rognure Prot gez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en fournissant des cabines ou des
50. o not cut or weld on containers that may have held combustibles Provide afire watch when working in an area where fire hazards may exist Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut under water or while using a water table DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dis sipated Trapped hydrogen gas that is ignited will cause an explosion Noise cause permanent hearing loss Plasma arc pro cesses can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent per manent loss of hearing To protect your hearing from loud noise wear pro tective ear plugs and or ear muffs Protect others in the workplace Noiselevels should be measured to be sure the deci bels sound do not exceed safe levels e Forinformation on how to test for noise see item 1 in Subsection 1 03 Publications in this manual GENERAL INFORMATION 12 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 p
51. o the diode bridge s being replaced Reinstall the Power Supply cover Test the Power Supply for proper operation 5 07 Rear Panel Parts Replacement Refer to Section 6 for parts list and overall detailed draw ing G Disconnect input power at the source and bleed down the system before attempting these proce dures A Pressure Gauge Replacement 1 2 Disconnect the gas input line from the Power Supply Remove the Power Supply cover per Subsection 5 04 A Disconnect the gas tube from the Pressure Switch Assembly Adapter Fitting Hold a wrench or simi lar tool against the locking ring on the Fitting and pull the tube to release it Disconnect the Filter Regulator Assembly as fol lows a Pull the Regulator Filter drain tube out of the hole in the base of the Power Supply b Release the securing ring on the top of the Regulator Filter Assembly c Move the Regulator Filter Assembly forward to disengage the inlet port and pressure gauge from the Power Supply rear panel Turn the Pressure Gauge to release it from the Regulator Filter Assembly Apply thread sealant to the threads of the replace ment Pressure Gauge NOTE Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small gas passages in the torch SERVICE 10 11 12 Thread the replacement Pressure Gauge into the Power Supply the Regulator Filter Assembly Tighten secure
52. oisture build up 5 Inspect input power cable for damage or exposed wires replace if necessary Weekly or Every 30 Cutting Hours 1 Check fan for proper operation and adequate air flow 2 Blow or vacuum dust and dirt out of the entire machine m CAUTION Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit Six Months or Every 720 Cutting Hours 1 Check the in line air filter s clean or replace as required 2 Check cables and hoses for leaks or cracks replace if necessary 3 Check all contactor points for severe arcing or pits replace if necessary APPENDIX A 4 Manual 0 2898 APPENDIX 5 TORCH CONNECTOR DIAGRAM ATC Male Connector ATC Female Receptacle Front Vie Front View ZEN Y SN 3 White D iy 7 Open 7 Open NS 2 ai 3 Switch Switch Le 31 2 orange 152 1 PIP NS D 1 MN 79 Open 6 Open NA 5 Ground lt y gt ilot A 03694 Manual 0 2898 A 5 APPENDIX APPENDIX 6 SYSTEM SCHEMATIC
53. ollow 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 2898 1 1 As AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the kind of metal being used coatings on the metal and the different processes You must be very careful when cutting or welding any 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
54. proper operation c Check torch switch for coninuity AC indicator flashing on start up indica tor OFF RUN SET switch in RUN position 1 lorchtip starter cartridge or electrode missing or badly worn a Check torch parts replace as needed 2 Dirty or defective starter cartridge a Check starter cartridge clean or replace as needed Manual 0 2898 H 4 5 3 Wire E8 not connected to PC Board terminal E8 a Check connection reconnect if necessary 4 PC board fault circuit defective a Replace PC board AC indicator flashes Temp indicator steady ON 1 Fan wire harness disconnected from terminal J4 on PC board a Check fan wire harness reconnect if necessary 2 Faulty fan or fan wire harness a Check fan and harness replace as needed AC indicator flashes TEMP indicator blinks slowly RUN SET switch in SET position 1 Fan is blocked a Check fan blades clear as needed 2 Faulty PC Board a Replace PC Board No gas flow AC indicator ON TEMP indicator OFF DC indicator OFF Gas indicator ON RUN SET switch in SET position 1 Inlet gas pressure too high over 120 psi 8 3 bar a Set inlet gas pressure below 120 psi 8 3 bar 2 Faulty RUN SET switch a Disconnect wires from RUN SET switch Test switch for continuity in SET position If no con tinuity in SET position replace switch 3 Faulty gas solenoid or solenoid wire harness a Disconnect solenoid wire harness from
55. r Supply front panel firmly Connect the wiring harness to terminal J2 on the PC Board Reinstall the Power Supply cover Connect the Power Supply to primary input power Test the Power Supply for proper operation 5 06 Left Side Internal Parts Replacement Refer to Section 6 Left Side Internal Replacement Parts G Disconnect input power at the source and bleed down the system before attempting these proce dures Manual 0 2898 A Diode Bridge Replacement 5 3 1 Remove the Power Supply cover per Subsection 5 04 A Label and remove the wires from the diode bridge to the PC Board Refer to the illustration Remove RTV silicone over the screw head secur ing the diode bridge to the Fan Panel Remove hardware securing the diode bridge to the Fan Panel Remove the diode bridge Refer to the illustration Position the diode bridge as shown Note the location of the notched area marked on the diode bridge Position the re placement diode bridge on the thermal pad on the Fan Panel Replace the thermal pad if it is dam aged Thermal Pad Mark Mark A 03494 SERVICE 10 Secure the diode bridge to the Fan Panel with the hardware removed previously Torque the hard ware to 15 in Ibs 1 7 Nm Apply silicone over the securing hardware Use care to avoid getting RTV on the electrical con nectors Refer to the illustration Connect wires from the PC Board t
56. ro tect your skin from the arc rays and sparks Keep helmet and safety glasses in good condition Replace lenses when cracked chipped or dirty Protect others in the work area from the arc rays Use protective booths screens or shields Use the shade of lens as suggested in the following per ANSI ASC Z49 1 Minimum Protective Suggested Arc Current Shade No 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 be used when the arc is hidden by the work piece 1 03 Publications Refer to the following standards or their latest revisions for more information 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Docu ments U S Government Printing Office Washington D C 20402 ANSI Standard Z49 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding So ciety 550 N W LeJeune Rd Miami FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Govern ment Printing Office Washington D C 20402 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCU PATION AND EDUCATIONAL EYE AND FACE PRO TECTION obtainable from American National Stan dards Institute 1430 Broadway New York NY 10018 ANSI Standard Z41 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the Ameri can Nation
57. s the Main Input and Internal Power Tests If the unit functions as described then proceed to para graph C If the unit does not function as described then note the symptom and proceed to Subsection 4 07 Main Input and Internal Power Problems 4 3 TROUBLESHOOTING C Pilot Arc Test 1 Close the torch switch and check the following Gas flows briefly then stops Gas flow re starts pilot arc starts DC indicator is ON This completes the Pilot Arc Test If the equipment oper ates as described then proceed to paragraph D If the equipment does not function as noted then note the symp tom and proceed to Subsection 4 08 Pilot Arc Problems D Main Arc Test Activate the Torch to establish a pilot arc Bring the torch to approximately 3 16 4 7 mm from the workpiece to establish the main cutting arc and note the following Main cutting arc starts Cutting arc transfers to workpiece This completes the Main Arc Test If the equipment op erates as described proceed to Subsection 4 07 If prob lems still persist then contact Technical Services If the equipment does not function as described note the symptom and proceed to Subsection 4 09 Main Arc Prob lems 4 07 Main Input and Internal Power Problems Locate your symptom below A Main power line fuses blow as soon as main disconnect is closed 1 Input power cable installed incorrectly or defective a Refer to the Appendix pages for PC Board Wir
58. section is To familiarize the service technician with the capabilities and limitations of the equipment To provide an overall understanding which will allow the technician in turn to properly train customer oper ating personnel 3 02 Specifications Design Features CutMaster 38 Power Supply Specifications 120 VAC 10 Single Phase 50 60 Hz 208 230 VAC 10 Single Phase 50 60 Hz Automatic Voltage Selection See Note 1 Cord with plug for 120VAC 20 Amp Single Phase input power 20 30 Amps continuously variable Power Supply Gas Filtering Ability Particulates to 20 Microns CutMaster 38 Power Supply Duty Cycle Note 2 104 F 40 C 39 e Bde w ma Amps SL 60 Torch Gas Requirements Compressed Air Clean dry oil free Note 3 25 psi 8 6 bar 5 psi 4 5 bar 00 scfh 141 5 Ipm Ambient Temperature Duty Cycle DO Voltage Curent HAE 2 3 2105 5 U 9 01519 o0 5 viols o o Power supply accepts 120 230 VAC input power No manual switching is required 2 Duty Cycle is the percentage of time the system can be operated without overheating Duty cycle is reduced if primary input voltage AC is low or the DC voltage is higher than shown in this chart 3 Air supply must be free of oil moisture and other contaminants Excessive oil and moisture may cause double arcing rapid tip wear
59. termi nal Jl on PC board Test resistance in wire har ness Resistance should be 20 ohm 5 ohm If resistance is not correct replace solenoid assem bly 4 Faulty PC board a Leave RUN SET switch in SET position Dis connect wire harness from terminal J1 on PC board Test voltage across pins of terminal J1 Voltage should be 10 13vdc If voltage is not correct replace PC board TROUBLESHOOTING K ACindicator steady ON TEMP indicator ON RUN SET switch in SET position 1 PC board temperature sensor disconnected or faulty a Check wire harness connection at terminal J5 on PC board Reconnect if necessary b Disconnect PC board temperature sensor wire harness from J5 on PC board Install a tempo rary jumper across the pins on PC board termi nalJ5 Check temperature indicator on Power Supply front panel If TEMP indicator is OFF replace PC board L No gas flow AC indicator ON GAS indicator OFF TEMP indicator OFF DC indicator OFF RUN SET switch in SET position 1 Gassupply not connected to unit a Connect gas supply 2 Gas supply not turned a Turn gas supply on 3 Gas pressure too low a Shut power supply off Set gas pressure on the power supply gas regulator to 65 psi 4 5 bar turn power supply back on 4 Faulty PC board a Disconnect pressure switch wire harness from terminal J9 on PC board Test for continuity between sockets 2 and 3 on the wire harness connector If gas pressure is
60. ting 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 indica tions and measurements The subsection is referenced by the troubleshooting guide for the specific test to be performed Manual 0 2898 B How to Use the Troubleshooting Guide The following information is a guide to help the Service Technician determine the most likely causes for various symptoms This guide is set up as follows 1 Perform operational check s on the equipment to iso late problem to possible circuit s per Subsection 4 06 Circuit Fault Isolation 2 Determine symptom and isolate to defective assem bly using the following format X Symptom Bold Type Any Special Instructions Text Type 1 Cause Italic Type a Check Remedy Text Type 3 Locate your symptom in the appropriate Subsection 4 Checkthe causes easiest listed first for the symptom 5 Check the remedies listed for each cause Remedies may have different specific information depending on the input voltage of the power supply 6 Repairas needed being sure to verify that unit is fully operational after any repairs NOTES Many signals are transferred between Power Sup ply components on cables If these cables become faulty they can cause various
Download Pdf Manuals
Related Search