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SERVICE

5-16

Manual 0-2869

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Summary of Contents for CE CutMaster 75

Page 1: ...Service Manual Plasma Cutting Power Supply CutMaster 75 CE CutMaster 75 March 22 2004 Manual No 0 2869 A 02990...

Page 2: ......

Page 3: ...ssion in this Manual whether such error results from negligence accident or any other cause Printed in the United States of America Publication Date Date March 22 2004 Record the following information...

Page 4: ...ply Options and Accessories 3 2 SECTION 4 SERVICETROUBLESHOOTING DIAGNOSTICS 4 1 4 01 Introduction 4 1 4 02 Periodic Inspection Cleaning Procedures 4 1 4 03 SystemTheory 4 1 4 04 Common Operating Prob...

Page 5: ...C PC BOARD LAYOUT A 3 APPENDIX 4 MAIN POWER PC BOARD LAYOUT A 4 APPENDIX 5 A 208 230 VOLT MAIN PC BOARD WIRING A 6 APPENDIX 5 B 400 V 460 V and 600 V MAIN PC BOARD WIRING A 7 APPENDIX 6 CD PC BOARD LA...

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Page 7: ...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...

Page 8: ...s in this manual PLASMAARC RAYS PlasmaArc 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...

Page 9: ...able from American National Standards Institute 1430 Broadway New York NY 10018 1 04 Note Attention et Avertissement Dans ce manuel les mots note attention et avertissement sont utilis s pour mettre e...

Page 10: ...er 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 pe...

Page 11: ...ue 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 1 06 Documents De Reference Consultez les normes suiva...

Page 12: ...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 13 Livret NWSA BIBLIOGRAPHIE SUR LA S...

Page 13: ...ent UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used CENELEC EN50199 EMC Product Standard for Arc Welding Equipment ISO IEC 60974 1 BS 638 PT10 EN 60 974...

Page 14: ...ws 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...

Page 15: ...ons 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 operatio...

Page 16: ...INTRODUCTION 2 2 Manual 0 2869...

Page 17: ...Front Panel LED Indicators AC TEMP GAS DC 3 Rear Panel Features Primary Input Power Cable Gas Pressure Regulator Filter Assembly Gas Supply Connection Grounding Stud CE Cutmaster 75 only 4 Input Power...

Page 18: ...ms Filters moisture and par ticulate matter from the air stream to at least 0 85 mi crons B Two Stage Air Line Filter A Two Stage In Line Air Filter for use on compressed air shop systems Filters mois...

Page 19: ...ON OFF switch is closed on the front panel the AC Indicator blinks for approximately eight sec onds then it becomes steady and the Main Contactor closes When the unit is at idle the AC indicator on t...

Page 20: ...he 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 Establ...

Page 21: ...6 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 spec...

Page 22: ...Power Supply 2 Turn on gas supply and adjust Power Supply Gas Regulator to 70 psi 4 8 bar 3 Set the Power Supply controls as follows ON OFF switch to OFF Down RUN SET switch to SET Down CURRENT contro...

Page 23: ...ng 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...

Page 24: ...4 9 Faulty ON OFF switch refer to Appendix 12 28 V AC Circuit Diagram Measure for 28 VAC on the Main PC Board be tween J18 5 to J18 6 a If voltage is not present replace the ON OFF Switch J23 1 J23 3...

Page 25: ...c is not present replace the Logic PC Board 3 Faulty Wiring or Faulty Logic PC Board Check for 12 vdc at Main PC Board pin J24 3 to J24 4 from the Logic PC Board Refer to Appen dix 4 Main PC Board Lay...

Page 26: ...er Torch Instruction Manual 2 Faulty Output Power PC Board a With ON OFF switch in the OFF position dis connect J39 from the Output Power PCB Acti vate the torch and check for continuity between J39 6...

Page 27: ...ct replace CD Board A 03175 J28 1 J28 2 CD PCB D No arc or intermittent arc in torch Gas flows Spark at gap on CD PC Board AC indicator ON TEMP indicator off GAS and DC indicators ON and CD enable ind...

Page 28: ...components with any part of the human body when power is applied 3 Keep away from any moving parts 4 Hot surfaces can cause severe burns Allow equip ment to cool before servicing 5 Electrostatic disch...

Page 29: ...ing any resistance checks 1 Input Diode Module Board Circuit Test a Remove AC power Refer to Appendix 5 Aor 5 B Main Power Wiring diagram b Check Input Diode for shorted input diode With an ohmmeter...

Page 30: ...E10 E23 E27 Open E10 E20 E27 E30 Open E20 E10 E30 E27 Diode Drop E4 E20 E23 E30 Open E20 E4 E30 E23 Diode Drop IGBT PCB A IGBT PCB B Indication can be twice other indications b The meter should indica...

Page 31: ...e INV ON indicator D21 blinks ON then OFF immediately perform the following test a Disconnect J28 from the CD PC Board to dis able the CD signal WARNING Connector J28 on the CD PC Board must be dis co...

Page 32: ...endix 3 If no voltage replace Logic PC Board If voltage is correct measure for approxi mately 6 vdc between points as in the fol lowing chart E11 J2A E11 J2B E19 J10A E19 J10B IGBT A IGBT B If voltage...

Page 33: ...nroll the rest of the band and peel the liner from the copper foil at the opposite end 3 Attach the copper foil to a convenient and exposed electrical ground 4 Connect the equipment primary cable grou...

Page 34: ...the inside of the cover 3 Remove the nut and washer from the ground stud on the inside of the cover 4 Installthereplacementcoverbyreversingtheabove steps B Tube Handle Replacement 1 Remove the cover...

Page 35: ...teps C RUN SET Switch Replacement 1 Remove the cover per subsection 5 04 A 2 Disconnect the two wires on the rear of the RUN SET Switch Note the location of each wire as shown A 02775 Wire 25 Wire 26...

Page 36: ...Contactor from the input cable or from the EMI filter on CE units 4 Disconnect all other wires connected to the Input Contactor 5 Remove the two nuts and washers securing the Input Contactor to the ba...

Page 37: ...ion and position 4 For IGBTs remove the small jumpers between the IGBT and the Main PC Board Transfer these jump ers to the replacement IGBT Label then remove all other wire connections to the Board s...

Page 38: ...put Diode Connections IGBT A Connector To Main PCB Connector IGBT B Connector To Main PCB Connector J3 J25 J3 J31 J7 J30 J7 J26 E9 E11 E10 E9 E11 E27 E19 E21 E20 E19 E21 E30 E12 E17 E4 E12 E17 E23 IGB...

Page 39: ...e locking ring on the Fitting and pull on the tube to release it 4 Remove the nut securing the Filter Regulator As sembly to the Regulator Mounting Bracket Re move the Filter Regulator Assembly from t...

Page 40: ...hen insert the re placement Filter Element open side first as shown 6 Replace Housing on Cover 7 Re attach gas supply hose NOTE If unit leaks between housing and cover inspect the O Ring for cuts or o...

Page 41: ...chassis 7 Replace the Rear Panel by reversing the above steps 8 If not already done attach the data tag s provided with the replacement Rear Panel Position these as on the original Rear Panel 5 08 Rig...

Page 42: ...side 8 Install the replacement Fan Assembly as follows a Fasten Fan s in position with the wiring con nectors at the bottom of the Fan s NOTE Only two screws are needed to attach the Fan to the Fan Sh...

Page 43: ...th a small piece of light duty tape Tape must cover no more than 1 8 3 mm of the edge of the ther mal pad Use the screw hole in the heatsink as a guide to position the pad 8 Secure replacement board a...

Page 44: ...right edge of its base into the slot and secure the assembly in place with the clip 11 Re install the Power Supply Cover G CD Transformer Replacement 1 Locate the CD PC BoardAssembly Label and dis con...

Page 45: ...wires from the CD Trans former to the CD PC Board 9 Remove the hardware securing the Pilot Control Relay in place Pull the Relay and its dust cover off the center chassis Set the dust cover aside 10 L...

Page 46: ...Shroud Assembly per sub section K J Output Inductor Assembly Replacement 1 Disengage the Heatsink Shroud per paragraph H 2 Disconnect the wires to the thermal switch on the Output Inductor 3 Remove he...

Page 47: ...he stud and nut on the bottom left edge fasten a wire stay to the Power Supply 6 Replace the grommets around the wire harnesses passing through the right rearward edge of the Heatsink Shroud 7 Reconne...

Page 48: ...SERVICE 5 16 Manual 0 2869...

Page 49: ...ht Side Internal Replacement Parts Section 6 08 Options and Accessories NOTE Parts listed without item numbers are not shown but may be ordered by the catalog number shown B Returns If a product must...

Page 50: ...8573 Hardware A 12 Screw 10 32 x 1 5 PPH swageform See Note 1 B 4 Washer 1 4 External Star See Note 1 C 4 Screw 1 4 20 x 3 4 Hex head See Note 1 D 1 10 32 kepnut w star washer See Note 1 E 1 10 32 x 3...

Page 51: ...Catalog 1 1 Knob Fluted Skirted 0 250 I D 9 8527 2 1 On Off Rocker Switch DPST SW1 8 3258 3 1 Run Set Switch Rocker SPST Center Off SW2 9 1042 4 1 Assembly Pot LED PCB 9 8004 5 1 Cable Work 6 AWG with...

Page 52: ...Circuit for 208 230 Volt 400 Volt and 460 Volt Power Supplies 9 8578 IGBT PCB Round Thermal Pad for 600 Volt Power Supplies 9 8646 IGBT PCB Round Thermal Pad 6 1 PCB Assembly Kit Input Diode Old style...

Page 53: ...Manual 0 2869 6 5 PARTS LISTS NOTE Illustration may vary slightly from unit 3 5 4 1 2 7 5 A 03188 2A OR 8 6 9...

Page 54: ...Element 9 4414 3 1 Regulator Mounting Bracket 9 7589 4 1 Input Power Cable for 208 230 Volt Power Supplies includes plug 9 8596 for 400 Volt Power Supplies 9 8562 for 400 Volt CE Power Supplies 9 855...

Page 55: ...Manual 0 2869 6 7 PARTS LISTS...

Page 56: ...CD Transformer T10 9 8582 4 1 Pilot Relay PCR 9 8574 5 1 Fan 220V 115 CFM M1 M2 9 7687 6 1 Assembly Main Transformer T5 for 208 230 Volt Power Supplies 9 8589 for 400 Volt Power Supplies 9 8603 for 4...

Page 57: ...Manual 0 2869 6 9 PARTS LISTS NOTE Illustration may vary slightly from unit 2 5 4 3 7 1 9 6 8 A 03189 Work Cable Heatsink Heatsink Heatsink Shroud Fan Shroud Bulkhead 5 9 PCR Cover...

Page 58: ...Not Shown 9 7535 1 Two Stage Air Filter Assembly 9 7527 1 Replacement First Stage Cartridge 9 1021 1 Replacement Second Stage Cartridge 9 1022 Not Shown 1 Extended Work Cable 50 ft 15 2 M 9 8529 1 Han...

Page 59: ...ss H or one time fuses like UL Class K5 B CE CutMaster 75 A Non CE CutMaster 75 Power Input Current Input Voltage Frequency 3 Ph 3 Ph Fuse Amps Wire mm2 Volts Hz kVA Amps 3 Ph 3 Ph CE CutMaster 75 400...

Page 60: ...h is within transfer distance 1 4 in 6 4mm of workpiece main arc will transfer After post flow Gas solenoid closes gas flow stops GAS indicator off ACTION Open external disconnect RESULT No power to s...

Page 61: ...Logic low PILOT ON signal P1 17 Logic low DC OK signal P1 18 Logic low OVERTEMP signal P1 19 Logic low AC OK signal P1 20 Return for torch switch P1 21 Logic low torch switch signal P1 22 12 vdc P1 2...

Page 62: ...M2 J16 1 Not Used J16 2 Not Used J17 1 Not Used J17 2 Not Used J23 J24 J32 J29 J33 J18 J43 J27 J11 J15 E1 E2 E3 E15 E7 J25 E10 J30 E20 E33 E4 E23 E32 J26 E27 E30 J31 J16 J17 TP4 TP6 A 03149 E22 Fuse L...

Page 63: ...nductor Temp Switch J33 1 Out J33 2 DC Com J33 3 Tip Sense J33 4 12vdc J33 5 CSR J33 6 Torch Switch J33 7 Torch Switch Return J33 8 CD Enable J43 1 12vdc J43 2 12vdc J43 3 DC Com J43 4 DC Com J43 5 MC...

Page 64: ...h To Heat Sink Temp Switch To Power Out put Board To PCR On Off Switch Run Set Switch To Pot LED PCB To Logic PCB via Extender Fuse To Main Transformer To Main Input Contactor Heatsink Temp Switch IGB...

Page 65: ...ch To Heat Sink Temp Switch To Power Out put Board To PCR On Off Switch Run Set Switch To Pot LED PCB To Logic PCB via Extender Fuse To Main Transformer Heatsink Temp Switch IGBT A IGBT B Input Diode...

Page 66: ...ENDIX A 8 Manual 0 2869 J28 1 12 vdc J28 2 CD Enable J28 3 Not Used J28 4 Not Used J28 5 E47 J28 6 Not Used J28 7 Not Used J28 8 E45 CD PC Board Signals APPENDIX 6 CD PC BOARD LAYOUT A 03086 E1 E2 J28...

Page 67: ...trol from Logic PC Board J27 3 Pot Low J14 4 12vdc J27 4 J14 5 Logic Low Signal for AC OK Indicator from Logic PC Board J27 5 J14 6 Logic Low Signal for GAS Indicator from Logic PC Board J27 6 J14 7 L...

Page 68: ...D LAYOUT A 03154 E21 E19 E12 E17 E11 E9 J3 J7 TP2B TP1B TP2A TP1A E21 E19 E11 E9 J3 J7 E12 E17 IGBT A IGBT B NOTE Refer to Appendix 5 A for wiring connec tions 208 230V Power Supplies Refer to Appendi...

Page 69: ...IX APPENDIX 9 INPUT DIODE PC BOARD LAYOUT A 03155 E18 E13 E5 E14 E16 E8 E6 NOTE Refer to Appendix 5 A for wiring connec tions 208 230V Power Supplies Refer to Appendix 5 B for wiring connec tions 400V...

Page 70: ...12 Manual 0 2869 APPENDIX 10 OUTPUT DIODE PC BOARD LAYOUT A 03152 E48 E50 E54 E53 E34 E39 E60 E56 Output Diode A Output Diode B E34 E39 E60 E56 E48 E50 E54 E53 NOTE Refer to Appendix 11 for wiring co...

Page 71: ...Enable J40 1 12vdc J40 2 CD Enable J40 3 Not Used J40 4 Not Used J40 5 E47 J40 6 Not Used J40 7 Not Used J40 8 E45 J41 1 Torch Switch J41 2 Not Used J41 3 Torch Switch J41 J39 E37 E47 E35 E62 J40 E52...

Page 72: ...2869 APPENDIX 12 28VAC CIRCUIT DIAGRAM 1 2 5 6 3 4 5 6 Main Power PC Board Auxiliary Transformer Voltage Protection J18 J24 12vdc W1 SOL ON OFF Switch A 03071 primary secondary Fuse 2 3 J23 K5 K4 J8...

Page 73: ...supply and pressure flow 4 Purge plasma gas line to remove any moisture build up 5 Inspect input power cable for damage or exposed wires replace if necessary Weekly or Every 30 Cutting Hours 1 Check...

Page 74: ...3 22 9 24 RUN SET SW 20 GATE DRIVE B 35 LED PCB 19X1604 27 J11 2 2 32 5 12 M2 7 4 8 W1 A 33 GATE DRIVE B RTN GAS SOLENOID 1 13 12 34 3 28VAC B 31 2 28VAC B S 3 27 D21 9 6 8 8 8 7 K4 21 2 12 20 8 25 D3...

Page 75: ...OLENOID SWITCH ON OFF SWITCH RUN SET C1 F3 F2 C1 D1 T5 B7 TS1 TS2 E1 F1 GCW W1 MAIN CONTACTOR F3 A2 TEMP SENSOR IGBT HEATSINK TEMP SENSOR INDUCTOR MAIN CURRENT SENSE L1 PCR T10 CD L1 E3 OUTPUT INDUCTO...

Page 76: ...PRESS GOOD 23 22 9 24 RUN SET SW 20 GATE DRIVE B 35 LED PCB 19X1604 27 J11 2 2 32 5 12 M2 7 4 8 W1 A 33 GATE DRIVE B RTN GAS SOLENOID 1 13 12 34 3 28VAC B 31 2 28VAC B S 3 27 D21 9 6 8 8 8 7 K4 21 2 1...

Page 77: ...T5 B7 TS1 TS2 E1 F1 GCW W1 MAIN CONTACTOR F3 A2 TEMP SENSOR IGBT HEATSINK TEMP SENSOR INDUCTOR MAIN CURRENT SENSE L1 PCR T10 CD L1 E3 OUTPUT INDUCTOR A10 MAIN TRANSFORMER T10 CD TRANSFORMER C10 08 21...

Page 78: ...28 15 ON OFF SW CHASSIS GND J43 19 J27 5 8 5 P11 FAN1 14 8 16 15 5 25 1 1 PR ESS GOOD 23 22 9 24 RUN SET SW 20 G ATE D R IVE B 35 LED PCB 19X1604 27 J11 2 2 32 5 12 M2 7 4 8 W1 A 33 G ATE D R IVE B R...

Page 79: ...2 3 72 E 58 J40 1 T 5 4 4 2 2 OUTPUT DIODE ASSEMBLY 19X1757 71 8 30 WORK 2 4 1 1 P3B P41 70 7 13 O 6 3 CD ENABLE 1 1 2 E 62 6 C D EN ABLE C 6 3 T5 J7A CHASSIS GND J7B 12VDC E 35 J42 5 H 2 7 1 3 T OR C...

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