Thermal Dynamics 51 CUTMASTER Service Manual Download | Manualshive

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TROUBLESHOOTING

4-10

Manual 0-2972

Art #A-03751

Fuse

(F1)

E1

E2

E3

E12

E11

E22

E35

E4

E13

E15

E16

E5

E20

E7

E19

E8

E21

E18

E10

E9

J1

J2

J5

J9

J3

J23

J4

J22

TP5

TP1

E23

E25

E26

E24

E28

E31

E32

E28

E30

E29

E33

TP13

IGBT

E38

E40

E39

E41

Output

Diode

E6

E27

E37

E43

E42

E36

E17

J21

E34

J20

E14

J26

J8

LT1

J18

J19

TP2

TP10

TP18

TP14

Main Printed Circuit Board Layout (Logic PCB Not Shown)

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Summary of Contents for 51 CUTMASTER

Page 1: ...PLASMA CUTTING SYSTEM 51 CUTMASTER Rev AB 02 Date June 15 2007 Manual 0 2972 Operating Features Art A 04611 Service Manual...

Page 2: ......

Page 3: ...ration 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...

Page 4: ......

Page 5: ...gulator Filter Assembly Specifications 3 4 SECTION 4 TROUBLESHOOTING 4 1 4 01 Introduction 4 1 4 02 Periodic Inspection Cleaning Procedures 4 1 4 03 SystemTheory 4 1 4 04 Common Operating Problems 4 2...

Page 6: ...C BOARD LAYOUT A 6 APPENDIX 5 PILOT BOARD LAYOUT A 8 APPENDIX 6 LED POT PC BOARD LAYOUT A 9 APPENDIX 7 IGBT CIRCUIT PC BOARD LAYOUT A 10 APPENDIX 8 INPUT DIODE PC BOARD LAYOUT A 11 APPENDIX 9 OUTPUT D...

Page 7: ...r 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...

Page 8: ...n 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 an...

Page 9: ...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 en re...

Page 10: ...u 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 person...

Page 11: ...es 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 suivantes...

Page 12: ...RIT 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 CU...

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

Page 14: ...sumable Parts such as tips electrodes shield cups o rings starter cartridges gas distributors fuses filters 2 Equipment that has been modified by an unauthorized party improperly installed improperly...

Page 15: ...e 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 th...

Page 16: ...INTRODUCTION 2 2 Manual 0 2972 This Page Left Blank...

Page 17: ...Duty Cycle 400 VAC 360 440 VAC Three Phase 50 60 Hz 460 VAC 414 506 VAC Single Phase 60 Hz 460 VAC 414 506 VAC Three Phase 60 Hz Power Supply includes input cable Cable for 208 230V input power inclu...

Page 18: ...Features Art A 03578 Work Cable and Clamp Handle and Leads Wrap Torch Leads Receptacle Control Panel Art A 03738 Input Power Cord Ports for Optional Automation Interface Cable Gas Inlet Port Gas Press...

Page 19: ...Panel Indicators AC When lighted indicates AC input power is present in thepower supply TEMP When lighted indicates the power supply is overheated GAS When lighted indicates that adequate input air pr...

Page 20: ...0 2972 3 04 Air Regulator Filter Assembly Specifications The following specifications apply to the Air Regulator Filter Assembly only 1 Operating Pressure 65 psi 4 5 bar 2 Maximum input air supply pr...

Page 21: ...N OFF switch is closed on the front panel the AC Indicator turns on The GAS indicator is ON when there is sufficient gas pressure in the power supply to enable power sup ply operation NOTE Minimum gas...

Page 22: ...of a cut being more square than the other Viewed along the direction of travel the right side of the cut is more square than the left E Dross When dross is present on carbon steel it is commonly refer...

Page 23: ...Power Prob lems Section 4 08 Pilot Arc Problems Section 4 09 Main Arc Problems Section 4 10 Test Procedures Subsection 4 10 includes specific test procedures and in dicator status identification table...

Page 24: ...low the instructions as given to iden tify the possible symptom s and the defective circuit Af ter repairs are complete run the following tests again to verify that the unit is fully operational 1 Con...

Page 25: ...lems still persist then contact Technical Services If the torch does not function as noted then note the symp tom and proceed to Subsection 4 09 Main Arc Problems 4 07 Main Input and Internal Power Pr...

Page 26: ...oper installation Do not overtighten 5 Main power line fuses blown a Replace main power line fuses 6 Improper input power cable connections inside Power Supply a Refer to System Schematic and correct...

Page 27: ...eplace Fan M1 4 Faulty Temperature Sensor Switch a Shut input power off Check IGBT Heatsink Temp Sensor TS1 Disconnect wire connector P2 from terminal J2 on Main PC Board Check connector pins 1 and 2...

Page 28: ...Switch located on the right side of the unit a If 12 vdc is present and pressure is above 50 psi 3 4 bar replace Gas Pressure Switch Solenoid Assembly Refer to Section 5 08 A b If pressure is above 50...

Page 29: ...n Out Diagrams Check torch switch continuity through sockets 3 and 4 NOTE In mechanized machine torch applications remote pendant control switch must also be closed I Gas cycles on and off when power...

Page 30: ...5 E16 E5 E20 E7 E19 E8 E21 E18 E10 E9 J1 J2 J5 J9 J3 J23 J4 J22 TP5 TP1 E23 E25 E26 E24 E28 E31 E32 E28 E30 E29 E33 TP13 IGBT E38 E40 E39 E41 Output Diode E6 E27 E37 E43 E42 E36 E17 J21 E34 J20 E14 J2...

Page 31: ...position of upper O ring Correct if necessary Upper Groove with Vent Holes Must Remain Open Threads Upper O Ring in Correct Groove Lower O Ring Art A 03725 3 Faulty IGBT a Measurebetweenthefollowingpo...

Page 32: ...Check and connect to proper input power line 4 Faulty Temperature Sensor Switch CAUTION Turn off input power for the following tests a Check IGBT Heatsink Temp Sensor TS1 Dis connect wire connector P2...

Page 33: ...he SET down position b Place a welding filter lens in front of the torch and turn on the air Any oil or moisture in the air will be visible on the lens Do not start an arc c Purge system If problem co...

Page 34: ...nted or rusty a Clean workpiece 4 Faulty Main PC Board or Logic Board a Measure for 0 vdc at TP2 to TP1 on the Logic Board when attempting to transfer Refer to Logic Board Layout If voltage goes to 0...

Page 35: ...printed circuit boards 6 Misaligned plugs can cause printed circuit board dam age Be sure plugs are properly aligned and completely seated 7 Excessive pressure can damage printed circuit boards Useonl...

Page 36: ...hmmeter positive lead to the anode of the diode and the negative lead to the cathode of the diode for forward bias testing refer to follow ing figure A properly functioning diode will conduct in the f...

Page 37: ...ndication L1 T1 Open L2 T2 Open 400 460V Only L2 T1 Open All Voltages If any test has resistance then replace the Main Contactor also E Main Input Contactor W1 Test Reconnect power and observe proper...

Page 38: ...not turn ON then replace the Logic PCB If the INV ON indicator turns ON then OFF imme diately the following test should be performed a Disconnect eight pin wire harness connector from the Pilot PC Boa...

Page 39: ...ensing a After checking all previous steps in Subsection 4 09 G jumper TP1 to TP2 on the Logic PCB b DisconnectwiresfromtheMainPCBoardasshown in the chart When the unit is turned on the DC light shoul...

Page 40: ...TROUBLESHOOTING 4 20 Manual 0 2972 This Page Left Blank...

Page 41: ...rst two folds of the band Wrap the adhesive side firmly around your wrist 2 Unroll the rest of the band and peel the liner from the copper foil at the opposite end 3 Attach the copper foil to a conven...

Page 42: ...ion 5 04 A 2 Remove the four bolts and star washers securing the tube handles to the base of the unit 3 Move the input power cable torch leads and work cable inside the handle then lift the base of th...

Page 43: ...over D POT LED PC Board Replacement Follow the antistatic procedures in Subsection 5 02 1 Remove the cover per Subsection 5 04 A 2 Remove Current Knob per procedures in Subsec tion 5 05 A 3 Disconnect...

Page 44: ...inPower PC Board 4 Install the replacement Logic PC Board by revers ing the above steps Note the following a The pins on the Logic Board must be fully seated in the J1 connector on the Main PC Board E...

Page 45: ...flat surface on the back of the re placement component with isopropyl alcohol 10 Install modules as follows a Put the replacement module in position and secure with the screw removed previously En sur...

Page 46: ...ent part is a thin metal pad Remove and discard any loose protective paper coverings from the pad CAUTION Protective coverings must be removed from the ther mal pad Installing a thermal pad with prote...

Page 47: ...rd if the PowerSupplyisturnedonitsrightsidefirst Torque the screws to 17 inch pounds 1 9 Nm Art A 03909 Auxiliary Transformer IGBT Output Diode Attachment Screws 1 3 9 5 4 2 6 7 8 10 11 12 9 Reconnect...

Page 48: ...Filter Element Replacement 1 Remove power from the power supply turn off the gas supply 2 Unscrew the bowl on the bottom of the Regulator Filter Assembly The filter element will be visible and still a...

Page 49: ...n 5 Hand tighten the two bolts evenly then torque each bolt to 20 30 in lbs 2 3 3 4 Nm 6 Slowly apply air pressure to the assembly check ing for leaks F Input Power Cable Replacement 1 Remove the cove...

Page 50: ...elease the hose from the Adapter Fitting on the right side of the Pressure Switch 6 Install the replacement Pressure Switch Solenoid Assembly by reversing the above steps Once in stalled the Solenoid...

Page 51: ...te the two tabs below the Main PC Board se curing the Fan Shroud to the Center Chassis Use a screwdriver to push these tabs down to release the Shroud 7 Label and disconnect cables at the following po...

Page 52: ...e front mounting screw securing the Output Inductor Assembly to the unit base 5 RemovegrommetfromFanShroudforbetteraccess to the Output Inductor Assembly rear mounting stud 6 Pass a magnetic socket wi...

Page 53: ...ion 6 07 Rear Panel Replacement Parts Section 6 08 Options and Accessories NOTE Parts listed without item numbers are not shown but may be ordered by the catalog number shown B Returns If a product mu...

Page 54: ...og 1 1 Cover with labels 9 7999 2 1 Tube roll handle 9 8320 Hardware A 8 Screw 10 32 x 1 2 PPH Swageform See Note 1 B 4 Washer 1 4 External Star See Note 1 C 4 Screw 1 4 20 x 3 4 Hex See Note 1 NOTES...

Page 55: ...ef Catalog 1 1 Knob Fluted Skirted 0 250 I D 9 8527 2 1 On Off Rocker Switch SW1 8 3258 3 1 Run Rapid Auto Restart Set Switch SW2 8 3259 4 1 Assembly Pot LED PCB 9 8004 5 1 Cable Work 6 awg with Clamp...

Page 56: ...bly Logic Board Non mechanized units 9 7996 4 1 PCB Assembly Logic Board Mechanized units 9 9439 5 1 PCB Kit IGBT Circuit 9 8540 1 Round Thermal pad 6 1 PCB Kit Output Diode 9 8539 1 Round Thermal pad...

Page 57: ...Manual 0 2972 6 5 PARTS LISTS NOTE Illustration may vary slightly from unit 1 4 5 3 7 Art A 03904 8 2A A E 6 OR B C B C 2B Input Diode Mounting Plate part of Center Chassis Center Chassis...

Page 58: ...7687 4 1 Assembly Main Transformer T5 9 8544 5 1 Assembly Output Inductor L1 9 8560 Hardware A 5 10 32 x 1 2 pph screw See Note B 1 10 External star washer See Note C 1 1 4 20 nut brass See Note D 3...

Page 59: ...Manual 0 2972 6 7 PARTS LISTS NOTE Illustration may vary slightly from unit Art A 03905 2 3 4 5 D A E A B A Heatsink 1...

Page 60: ...1 Assembly Filter Regulator 9 7514 2 1 Regulator Filter Replacement Element 9 4414 3 1 Regulator Mounting Bracket 9 7589 4 1 Input Power Cable For 208 230 Volt Units 8 4384 For 400 Volt Units non CE 9...

Page 61: ...StageAir FilterAssembly 9 7527 1 Replacement First Stage Cartridge 9 1021 1 Replacement Second Stage Cartridge 9 1022 1 Wheel Kit 9 8510 Not shown 1 Extended Work Cable 50 ft 15 2 m 9 8529 1 Hand Pen...

Page 62: ...ed under U S Patent No s 5120930 and 5132512 Catalog Number Description 9 8235 Shield Cap Drag 50 60A 9 8236 Sheild Cap Drag 70 100A 9 8237 Shield Cup Body 9 8238 Shield Cap Machine 50 60A 9 8239 Shie...

Page 63: ...s H or one time fuses like UL Class K5 Voltage Freq 1 Ph 3 Ph 1 Ph 3 Ph Volts Hz kVA kVA Amps Amps 1 Ph 3 Ph 1 Ph 3 Ph 1 Ph 3 Ph 208 60 9 39 60 10 10 230 60 9 37 60 10 10 400 50 8 11 15 12 12 400 60 8...

Page 64: ...em is ready for operation ACTION RUN Rapid Auto Restart SET switch to SET RESULT Gas flows to set pressure ACTION RUN Rapid Auto Restart SET switch to RUN for most applications or to Rapid Auto Restar...

Page 65: ...Manual 0 2972 A 3 APPENDIX This Page Left Blank...

Page 66: ...APPENDIX A 4 Manual 0 2972 Art A 03883 TP6 D8 TP1 TP8 TP9 TP10 TP3 TP4 TP2 TP5 TP7 P1 1 to P1 36 P1 7 APPENDIX 3 LOGIC PC BOARD LAYOUT...

Page 67: ...19 Logic Low AC OK Signal to Main PCB P1 20 Return for Torch Switch P1 21 Logic Low Torch Switch Signal P1 22 12 vdc P1 23 To Current Control Pot P1 24 Current Control P1 25 Current Control Return P1...

Page 68: ...ogic PCB J1 18 Logic Low OVERTEMP signal from Logic PCB J1 19 Logic Low AC OK signal from Logic PCB J1 20 Return J1 21 Logic Low torch switch signal to Logic PCB J1 22 12 vdc to Logic PCB J1 23 Pot Hi...

Page 69: ...or W1 J4 6 28VAC to Main Contactor W1 J4 7 12V J4 8 Ground from Pilot Board J4 9 Current Sense to Pilot Board J4 10 ISense to Pilot Board J5 1 28VACA for test only J5 2 Ground for test only J5 3 28VAC...

Page 70: ...J4 9 J28 6 Not Used J28 7 Not Used J28 8 I Sense to Main PC Board Connector J4 10 APPENDIX 5 PILOT BOARD LAYOUT 2 Pin Receptacle J1 No Receptacle E58 E62 J28 E58 E62 J28 Art A 03880 OR NOTES 1 Pilot P...

Page 71: ...J22 3 Pot Low J14 4 12vdc J22 4 J14 5 Logic Low Signal for AC OK Indicator from Logic PC Board J22 5 J14 6 Logic Low Signal for GAS Indicator from Logic PC Board J22 6 J14 7 Logic Low Signal for TEMP...

Page 72: ...APPENDIX A 10 Manual 0 2972 APPENDIX 7 IGBT CIRCUIT PC BOARD LAYOUT A 02851 E31 TP13 TP14 E32 E28 E30 E29 E33...

Page 73: ...Manual 0 2972 A 11 APPENDIX APPENDIX 8 INPUT DIODE PC BOARD LAYOUT Art A 03882 E18 E13 E14 E5 E16 E8 E6...

Page 74: ...APPENDIX A 12 Manual 0 2972 APPENDIX 9 OUTPUT DIODE PC BOARD LAYOUT A 02853 E37 E36 E38 E40 E43 E42 E39 E41...

Page 75: ...Manual 0 2972 A 13 APPENDIX This Page Left Blank...

Page 76: ...al Remote Current Control To ON OFF Switch and Mode Switch Fuse Logic Board Connector J1 Solenoid Pressure Switch Contactor Harness Fan Harness To Input Contactor E14 E16 E8 E6 E18 E13 Art A 03752 E1...

Page 77: ...rrent Control To ON OFF Switch and Mode Switch Fuse Logic Board Connector J1 Solenoid Pressure Switch Contactor Harness Fan Harness To Input Contactor E14 E16 E8 E6 E18 E13 E5 Art A 03753 E1 E2 E3 To...

Page 78: ...ENDIX 11 28VAC CIRCUIT DIAGRAM 1 2 5 6 3 4 5 6 Main Power PC Board Auxiliary Transformer Voltage Protection CRT 12 Regulator J3 J4 12vdc W1 SOL ON OFF Switch A 02770 primary secondary 0 5A Fuse 2 3 J5...

Page 79: ...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 80: ...1 Black PIP Negative Plasma 8 Ground ATC Male Connector Front View A 03701 B Mechanized Machine Torch Pin Out Diagram ATC Female Receptacle Front View ATC Male Connector Front View Negative Plasma 3...

Page 81: ...8 7 1 2 5 6 4 3 8 7 Torch Switch Green White To Power Supply Circuitry B Mechanized Torch Connection Diagram Torch Unshielded Mechanized SL100 Machine Torch Leads Leads with ATC Connector and Remote...

Page 82: ...4 5 2 3 B A 1 2 3 TORCH SW TORCH SW RTN PIP PIP RTN 4 1 3 2 78 79 80 81 4 1 3 2 3 4 2 1 8 CSR TORCH SWITCH TORCH SWITCH Vo 1 2 1 2 GATE DRIVE B RTN GATE DRIVE B GATE DRIVE A RTN GATE DRIVE A J21 J20...

Page 83: ...ATION D Lilja L1 REL ASSY 19X1721 J19 J18 P18 P19 WORK ASSY 19X2086 J28 PILOT BOARD T O R C H OUTPUT INDUCTOR IGBT BOARD NOTES UNLESS OTHERWISE SPECIFIED 1 DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS IS...

Page 84: ...2V GATE DRIVE B RTN GATE DRIVE B GATE DRIVE A RTN GATE DRIVE A CSR ISENSE FILTERING R94 460V R93 400V F1 1 4A 500V T1 K3 K4 K4 K4 K3 28VAC B 28VAC A OR E34 E17 PS1 MAIN CONTACTOR PRESSURE SWITCH GAS S...

Page 85: ...1 4A 500V FNQ M1 FAN 4 5 220VAC B3 C2 B2 PS1 PRESSURE SWITCH SOL1 GAS SOLENOID SWITCH ON OFF SWITCH RUN SET RAR F5 F5 D2 E2 B3 5 C 5 T TS1 TS2 E6 D Lilja W1 MAIN CONTACTOR TEMP SENSOR IGBT HEATSINK T...

Page 86: ...er ECO B016 Added c n for logic board for mechanized units Updated torque spec for replacement input diode per ECO 101948 Added publica tion history Started using new cover styles 9 29 06 AA 01 Added...

Page 87: ...trict Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jln Batu Arang 48000 Rawang Selangor Darul Eh...

Page 88: ...Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St Louis MO 63017 Telephone 636 728 3000 Email TDCSales Thermadyne com www thermadyne com...

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