Thermal Dynamics CUTMASTER 151 Operating Manual Download

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SERVICE

5-28

Manual 0-4691

C. RUN / RAPID AUTO RESTART / SET Switch (SW2) Replacement

1. Remove the power supply cover per Section 5.09-A.

2. Disconnect the wires on the rear of the Switch. Note the location of each wire, as shown:

Art # A-03906

Wire #25

Wire #26

Top clip

Wire #46

3. Squeeze together the clips on the top and bottom of the Switch, then remove the switch through the Front Panel.

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

5. Reinstall the power supply cover.

D. POT/LED PC Board Replacement

1. Remove the power supply cover per Section 5.09-A.

2. Remove Current Knob .

3. Disconnect wire harness Connector from POT/LED PC Board.

4. Remove PC Board from standoffs.

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

6. Reinstall the power supply cover.

Summary of Contents for CUTMASTER 151

Page 1: ...151 Rev AF 01 Date April 2 2007 Manual 0 4691 Operating Features Operating Manual AUTOMATED PLASMA CUTTING SYSTEM CUTMASTER Art A 04611 SL100SV PLASMA CUTTING MACHINE TORCH ...

Page 2: ...e 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 ...

Page 3: ...namics com Copyright 2004 2005 2006 2007 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or...

Page 4: ......

Page 5: ...Torch Parts Selection 3 9 3 08 Power Supply Connection to SC 11 Standoff Control 3 10 3 09 Power Supply Connection to Alternate Standoff Control 3 11 3 10 Automation Interface PC Board Set up 3 13 3 11 Optional Remote Current Control Harness Installation 3 14 SECTION 4 OPERATION 4 1 4 01 Product Features 4 1 4 02 Preparations For Operating 4 2 4 03 Selection Inspection and Replacement of Consumabl...

Page 6: ...r Supply Front Panel Replacement Parts 6 4 6 07 Rear Panel Replacement Parts 6 5 6 08 Power Supply Left Side Internal Replacement Parts 6 6 6 09 Right Side Internal Replacement Parts 6 8 6 10 Torch Replacement Parts 6 10 6 11 Torch Replacement Parts 6 12 6 12 Torch Consumables 6 14 6 13 Torch Spare Parts Kits 6 14 6 14 Complete Torch Assembly Replacement 6 16 6 15 Torch Options Accessories 6 16 PA...

Page 7: ... CNCHARNESS A 17 APPENDIX18 MAINPCBOARDLAYOUT A 18 APPENDIX19 MAINPCBOARDWIRINGLAYOUT 208 230 VoltPOWERSUPPLIES A 20 APPENDIX20 MAINPCBOARDWIRINGLAYOUT 400 V 415 V 460 V 600 VPOWERSUPPLIES A 21 APPENDIX21 LOGICBOARDLAYOUT A 22 APPENDIX22 POT LEDBOARDLAYOUT A 23 APPENDIX23 OUTPUTDIODELAYOUT A 24 APPENDIX24 OUTPUTDIODEWIRINGDIAGRAM A 25 APPENDIX25 PILOTBOARDLAYOUT A 26 APPENDIX26 28VACCIRCUITDIAGRAM...

Page 8: ......

Page 9: ...GASESANDFUMES Gasesandfumesproducedduringtheplasmacuttingprocess canbedangerousandhazardoustoyourhealth Keepallfumesandgasesfromthebreathingarea Keep yourheadoutoftheweldingfumeplume Useanair suppliedrespiratorifventilationisnotad equatetoremoveallfumesandgases Thekindsoffumesandgasesfromtheplasmaarcde pendonthekindofmetalbeingused coatingsonthe metal and the different processes You must be very c...

Page 10: ...as canbeeliminatedordissipated Trappedhydrogengas thatisignitedwillcauseanexplosion NOISE Noisecancausepermanenthearingloss Plasmaarcprocesses cancausenoiselevelstoexceedsafelimits Youmustprotect yourearsfromloudnoisetopreventpermanentlossofhear ing Toprotectyourhearingfromloudnoise wearprotective earplugsand orearmuffs Protectothersinthework place Noiselevelsshouldbemeasuredtobesurethedecibels so...

Page 11: ...Quincy MA 02269 10 NFPAStandard 51B CUTTING AND WELDING PRO CESSES obtainable from the National Fire ProtectionAs sociation BatterymarchPark Quincy MA 02269 11 CGAPamphletP 1 SAFEHANDLINGOFCOMPRESSED GASESINCYLINDERS obtainablefromtheCompressed GasAssociation 1235JeffersonDavisHighway Suite501 Arlington VA22202 12 CSAStandardW117 2 CODEFORSAFETYINWELDING ANDCUTTING obtainablefromtheCanadianStandar...

Page 12: ...lénium béryllium manganèse vanadium Lisez toujours les fiches de données sur la sécurité des matières sigleaméricain MSDS celles cidevraientêtre fournies avec le matériel que vous utilisez Les MSDS contiennentdesrenseignementsquantàlaquantitéetla naturedelafuméeetdesgazpouvantposerdesdangersde santé Pourdesinformationssurlamanièredetesterlafuméeet les gaz de votre lieu de travail consultez l artic...

Page 13: ...otection en bon état Remplacez toute lentille sale ou comportant fissure ou rognure Protégez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en fournissant des cabines ou des écrans de protection Utilisezlanuancedelentillequiestsuggèréedanslerec ommendation qui suivent ANSI ASC Z49 1 Nuance Minimum Nuance Suggerée Courant Arc Protective Numéro Numéro Moins de 300...

Page 14: ...rme70delaNFPA CODEELECTRIQUENATIONAL disponibleauprèsdelaNationalFireProtectionAssocia tion BatterymarchPark Quincy MA02269 10 Norme51BdelaNFPA LESPROCÉDÉSDECOUPEET DESOUDAGE disponibleauprèsdelaNationalFirePro tectionAssociation BatterymarchPark Quincy MA02269 11 BrochureGCAP 1 LAMANIPULATIONSANSRISQUE DESGAZCOMPRIMÉSENCYLINDRES disponible auprèsdel AssociationdesGazComprimés Compressed GasAssoci...

Page 15: ... 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 EN50192 EN50078 applicable to plasma cutting equipment and associ ated accessories For environments with increased hazard of electrical shock Power Supplies bearing the S mark conform to EN50192 when u...

Page 16: ...ble Parts such as tips electrodes shield cups o rings starter cartridges gas distributors fuses filters 2 Equipment that has been modified by an unauthorized party improperly installed improperly operated or misused based upon industry standards In the event of a claim under this warranty the remedies shall be at the discretion of Thermal Dynamics Corporation 1 Repair of the defective product 2 Re...

Page 17: ...sly Adjustable CutMaster 151 Power Supply Specifications 208 230 VAC 187 253 VAC Single Phase 50 60 Hz 460 VAC 414 506 VAC Single Phase 50 60 Hz Input Power 400 VAC 360 440 VAC Single Phase 50 60 Hz 400 VAC 360 440 VAC Three Phase 50 60 Hz 600 VAC 517 632 VAC Three Phase 60 Hz 415 VAC 370 460 VAC Three Phase 50 Hz 415 VAC 370 460 VAC Single Phase 50 Hz NOTE The duty cycle will be reduced if the pr...

Page 18: ...ions Input Power Input Current Input Suggested Sizes See Notes Voltage Freq 1 Ph 3 Ph 1 Ph 3 Ph Fuse Amps Volts Hz kVA kVA Amps Amps 1 Ph 3 Ph 1 Ph 3 Ph 400 415 50 20 48 50 10 400 415 50 11 26 30 4 Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electrical Code CE CutMaster 151 Input Wiring Specifications Wire mm2 NOTES Refer to Local and...

Page 19: ... Leads Wrap Torch Leads Receptacle Control Panel 2 04 Power Supply Features Art A 04214 Input Power Cord Gas Inlet Port Gas Pressure Regulator Filter Assembly Gas Pressure Gauge CPC Connector for Thermal Dynamics CNC Controller Knockout for Alternate CNC Controller Wire Harness ...

Page 20: ...e power supply C High Pressure Regulators High pressure regulators are available The regulators are used to set the proper compressed air pressure NOTE Regulators should not be installed with In Line Air Filters D Extended Work Cable with Clamp As an alternative to the standard 20 ft 6 1 m work cable clamp on the power supply a 50 ft 15 2 m work cable with clamp is available E Multi Purpose Cart R...

Page 21: ...essure 125 psi 8 6 bar Gas Flow 300 500 scfh 142 235 lpm SL100SV Machine Torch Specifications Gas Requirements Torch Leads Lengths NOTE Operating pressure varies with operating amperage and torch leads length Torch duty cycle is greater than power supply duty cycle Plasma Power Supply Used With Thermal Dynamics CutMaster 51 CutMaster 81 CutMaster 101 CutMaster 151 Torch Ratings 25 7 6 m with ATC C...

Page 22: ...switch 12 vdc circuit rating E Direct Contact Hazard For exposed tip the recommended standoff is 3 16 inches 4 7 mm 2 07 Torch Options and Accessories These items can adapt a standard system to a particular application or further enhance performance refer to Section 6 for ordering information Spare Parts Kits Various kits containing replacement consumable torch parts Pinion Assembly for machine to...

Page 23: ...orch Head Detail By forcing the plasma gas and electric arc through a small orifice the torch delivers a high concentration of heat to a small area The stiff constricted plasma arc is shown in Zone C Direct current DC straight polarity is used for plasma cutting as shown in the illustration Zone A channels a secondary gas that cools the torch This gas also assists the high velocity plasma gas in b...

Page 24: ...ng arc The negative output is connected to the torch electrode through the torch lead The positive output is connected to the workpiece via the work cable and to the torch through a pilot wire E Parts In Place PIP The torch leads include a Parts In Place PIP circuit When the torch shield cup is properly installed it closes a switch The torch will not operate if this switch is open A 03504 PIP Swit...

Page 25: ... Options The Power Supply includes a handle for hand lifting only Be sure unit is lifted and transported safely and securely WARNINGS Do not touch live electrical parts Disconnect input power cord before moving unit FALLING EQUIPMENT can cause serious personal injury and can damage equipment HANDLE is not for mechanical lifting Only persons of adequate physical strength should lift the unit Lift u...

Page 26: ...nnecttheinputpowercable orclosethemaindisconnectswitch tosupplypowertothesystem B Connections to 400 Volt 415V 460 Volt or 600 Volt Three Phase Power These Power Supplies are equipped with a four conductor input power cable for three phase input power The 400 Volt or 460 Volt Power Supply will accept Single Phase input power with a change of input power cable 1 Check your power source for correct ...

Page 27: ...fertoSection2forpowercablespecifications CAUTION The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements refer to table in Section 2 03 5 Strip back the insulation on the individual wires 6 Connect to main input contactor as follows Line 1 wire to terminal L1 Line 3 wire to terminal L3 7 ConnectthegroundwiretoGro...

Page 28: ...ectionisthesameforcompressedairfromacompressorfrom highpressurecylinders Refertosubsection3 4 Bor3 4 Cifanadditionalairlinefilteristobeinstalled 1 Connect the air line to the inlet port The illustration shows typical fittings as an example Other fittings can be used NOTE For a secure seal apply thread sealant to the fitting threads according to manufacturer s instructions Do not use Teflon tape as...

Page 29: ...ion Optional Two Stage Filter Installation C Using High Pressure Air Cylinders When using high pressure air cylinders as the air supply 1 Refer to the manufacturer s specifications for installation and maintenance procedures for high pressure regula tors 2 Examine the cylinder valves to be sure they are clean and free of oil grease or any foreign material Briefly open each cylinder valve to blow o...

Page 30: ...torch 1 Align theATC male connector on the torch lead with the female receptacle Push the male connector into the female receptacle The connectors should push together with a small amount of pressure 2 Secure the connection by turning the locking nut clockwise until it clicks DO NOT use the locking nut to pull the connection together Do not use tools to secure the connection 3 Thesystemisreadyforo...

Page 31: ...st the quality of air 1 PuttheON OFFswitchintheON up position 2 PuttheRUN RAPIDAUTORESTART SETswitchintheSET down position 3 Placeaweldingfilterlensinfrontofthetorchandturnontheair Anyoilormoistureintheairwillbevisibleonthelens Donotstartanarc Art A 04254 1 2 ...

Page 32: ... pinch block assembly 1 Mount the torch assembly on the cutting table 2 To obtain a clean vertical cut use a square to align the torch perpendicular to the surface of the workpiece A 02585 Workpiece Square Pinch Block Assembly MachineTorchSet Up 3 Thepropertorchparts shieldcupbody shieldcap tip startcartridge andelectrode mustbeinstalledforthetypeof operation RefertoSection3 07 TorchPartsSelection...

Page 33: ...torchforproperconsumableparts Thepartssuppliedinthetorchmaynotbecorrectfortheoperator schosen amperagelevel Thetorchpartsmustcorrespondwiththetypeofoperation Art A 04173 Electrode Start Cartridge Tip Ohmic Clip If Installed Torch Head Shield Cup Body Shield Cap Deflector ...

Page 34: ...mationInterfacePCBoardconnectedtoaCPCconnectoronthepowersupplyrearpanel ForconnectiontotheThermalDynamicsSC 11StandoffControl alignandconnectthecablefromtheStandoffControltothe CPCconnector Checkforasecureconnection CPC Connector for Thermal Dynamics CNC Controller Art A 04075 Connector for SC 11 Standoff Control CNC ...

Page 35: ...nnectiontoalternateCNCcontrols ToconnectanalternateCNCControltothePowerSupply 1 RemovethePowerSupplyCover 2 Carefullyopenthelowerknockout belowthefactory installedCNCconnector onthePowerSupplyrearpanel CPC Connector for Thermal Dynamics CNC Controller Art A 04178 Knockout for Alternate CNC Controller 3 Installacustomer suppliedthrough holeprotector StrainRelief inthelowerknockouthole 4 Routethewir...

Page 36: ... i d e d O u t p u t P o s i t i v e D i v i d e d O u t p u t N e g a t i v e L o g i c C o m m o n O p e n O p e n O p e n O p e n O p e n O p e n O p e n O p e n A r c V o l t s P o s i t i v e P r o p r i e t a r y A r c V o l t s N e g a t i v e P r o p r i e t a r y R e m o t e C u r r e n t C o n t r o l O p t i o n a l R e m o t e C u r r e n t C o n t r o l O p t i o n a l R e m o t e C u...

Page 37: ...Control ForoperationwithanyotherCNCequipment refertotheCNCsystemdocumentstodeterminethedivisionfactortheCNC systemrequires Proceedasfollows 1 SettheinterfacecontrolboardswitchesasindicatedintheappropriatechartintheAppendixpages Thedivisionfactors arelistedintheright handcolumnofeachchart Automation Interface PC Board Art A 03902 Pilot PC Board Output Power PC Board Automation Interface PC Board Ar...

Page 38: ...heharnessasfollows To Pot LED Board Receptacle J14 To Automation Interface Board Receptacle J3 To Main PC Board Receptacle J27 Connector Plugs Art A 03945 4 Ensure that the wire harness will not interfere with the fit of the power supply cover against the top edge of the power supply center chassis Use wire ties as needed to secure the wire harness NOTE Installation of this harness disables the ou...

Page 39: ...dmetalorintrimmingoperations SET down positionisforsettinggaspressureandpurginglines AC Indicator Steadylightindicatespowersupplyisreadyfor operation Blinkinglightindicatesunitisinpro tectiveinterlockmode Shutunitoff shutoffor disconnectinputpower correctthefault andre starttheunit RefertoSection5fordetails TEMP Indicator Indicator is normally OFF Indicator is ON when internal temperature exceeds ...

Page 40: ...Supply C Check Primary Input Power Source 1 Check the power source for proper input voltage Make sure the input power source meets the power re quirements for the unit per Section 2 Specifications 2 Connect the input power cable or close the main disconnect switch to supply power to the system D Gas Selection Ensure compressedairsourcemeetsrequirements refertoSection3 4 Checkconnectionsandturngass...

Page 41: ...PowerSupplyON OFFswitchtotheON up position ACindicator turnson Gas indicator turns on if there is sufficient gas pressure for power supply operation NOTE Minimum pressure for power supply operation is lower than minimum for torch operation 1 Art 04255 ...

Page 42: ...n Gaswillflow Art A 04254 1 2 2 Adjustgaspressureperthesettingschart Leads Length Up to 25 7 6 m Over 25 7 6 m 40A Cutting 65 psi 4 5 bar 70 psi 4 8 bar 60A Cutting 70 psi 4 8 bar 75 psi 5 2 bar 80A Cutting 65 psi 4 5 bar 70 psi 4 8 bar CutMaster 151 Gas Pressure Settings Art A 04181 65 75 psi 4 5 5 2 bar Pressure Control Knob ...

Page 43: ...osition whenthetorchleavestheworkpiecethepilotarcrestartsinstantly andthecuttingarcrestartsinstantlywhenthepilotarc contactstheworkpiece Usethe RapidAutoRestart positionwhencuttingexpandedmetalorgratings orintrimming operationswhenanuninterruptedrestartisdesired J Typical Cutting Speeds Cuttingspeedsvaryaccordingtotorchoutputamperage thetypeofmaterialbeingcut andoperatorskill Outputcurrentsettingo...

Page 44: ...h or torch leads DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON Art A 04173 Electrode Start Cartridge Tip Ohmic Clip If Installed Torch Head Shield Cup Body Shield Cap Deflector ConsumableParts 1 Unscrewandremovetheshieldcupassemblyfromthetorchhead Inspectthecupfordamage Wipeitcleanorreplaceif damaged NOTES The shield cup holds the tip and start cartri...

Page 45: ...sive wear Replace the electrode if wear is greater than 0 062 1 5 mm or if the wear is excessively off center Refer to the following figure Electrode Wear Art A 04057 0 062 1 5 mm ElectrodeWear 5 ReinstalltheElectrodebypushingitstraightintothetorchheaduntilitclicks 6 Reinstall the start cartridge and tip into the torch head 7 Handtightentheshieldcupuntilitisseatedonthetorchhead Ifresistanceisfeltw...

Page 46: ...h ofthefaceofthecut B Nitride Build Up Nitridedepositscanbeleftonthesurfaceofthecutwhennitrogenispresentintheplasmagasstream Thesebuildupsmay createdifficultiesifthematerialistobeweldedafterthecuttingprocess C Bevel Angle The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate A perfectly perpendicular cut would result in a 0 bevel angle D Top Edge Round...

Page 47: ...an adversely affect tip life as well as shield cup life Standoff may also significantly affect the bevel angle Reducing standoff will generally result in a more square cut C Edge Starting For edge starts hold the torch perpendicular to the workpiece with the front of the tip near not touching the edge of the workpiece at the point where the cut is to start When starting at the edge of the plate do...

Page 48: ...eavy bead but does not adhere tightly to the cut edge and can be easily scraped off 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 produce slow speed dross Any resultant cleanup can be accomplished by scraping not grinding 4 06 Torch Operation A Cutt...

Page 49: ... recom mended for air plasma on mild steel 3 Trailing Arc The trailing arc is directed in the opposite direction as torch travel Standoff Distance Straight Arc Trailing Arc Leading Arc Direction of Torch Travel A 02586 Machine Torch Operation For optimum smooth surface quality the travel speed should be adjusted so that only the leading edge of the arc column produces the cut If the travel speed i...

Page 50: ...required Torchtravelshouldnotbeenableduntilthearc penetratesthebottomoftheplate Asmotionbegins torchstandoffshouldbereducedtotherecommended1 8 1 4inch 3 6mm distanceforoptimumspeedandcutquality Cleanspatterandscalefromtheshieldcupandthetipassoonaspossible Sprayingordippingtheshieldcupinanti spattercompoundwillminimizetheamountofscalewhichadherestoit 4 07 Cutting Parameters Cuttingspeeddependsonmat...

Page 51: ...meter littleornodross smoothcutsurface Good Slightbevel 0 10 slightlywiderkerf 2 1 2xtip orificediameter somedross easilyremoved medium smoothcutsurface slighttopedgerounding 4 08 Cutting Specifications Cutting Range Material Most Metals Up to 1 inch 25 4 mm Speed 10 ipm 0 25 mpm Pierce Rating Material Carbon Steel Thickness 3 8 inch 9 5 mm Transfer Distance 3 8 inch 9 5 mm Bevel Cut Capability De...

Page 52: ...ild Steel SL100 Torch with Exposed Tip Starter Cartridge 9 8213 Electrode 9 8215 20A 9 8205 30A 9 8206 40A 9 8208 50 55A 9 8209 60A 9 8210 70A 9 8231 80A 9 8211 100A 9 8212 Tips Art A 04671 Shield Cap Deflector 9 8243 Ohmic Clip 9 8224 Shield Cup Body 9 8237 ...

Page 53: ...8 177 6 4511 0 188 4 8 9 8210 60 70 0 2 4 8 0 20 114 0 19 4 8 137 3480 0 250 6 4 9 8210 60 70 0 2 4 8 0 30 116 0 19 4 8 82 4 2093 0 375 9 5 9 8210 60 70 0 2 4 8 0 50 118 0 19 4 8 42 4 1077 0 500 12 7 9 8210 60 70 0 2 4 8 0 75 119 0 19 4 8 26 3 668 0 625 15 9 9 8210 60 70 NR NR NR 127 0 19 4 8 17 4 442 0 750 19 1 9 8210 60 70 NR NR NR 126 0 19 4 8 16 406 1 000 25 4 9 8210 60 70 NR NR NR 128 0 19 4 ...

Page 54: ...inless Steel SL100 Torch with Exposed Tip Starter Cartridge 9 8213 Electrode 9 8215 20A 9 8205 30A 9 8206 40A 9 8208 50 55A 9 8209 60A 9 8210 70A 9 8231 80A 9 8211 100A 9 8212 Tips Art A 04671 Shield Cap Deflector 9 8243 Ohmic Clip 9 8224 Shield Cup Body 9 8237 ...

Page 55: ... 80 103 2616 2 0 188 4 8 9 8210 60 70 0 2 4 8 0 20 112 0 19 4 80 90 2286 0 0 250 6 4 9 8210 60 70 0 2 4 8 0 30 113 0 19 4 80 68 8 1747 5 0 375 9 5 9 8210 60 70 0 2 4 8 0 50 115 0 19 4 80 35 889 0 0 500 12 7 9 8210 60 70 0 2 4 8 0 75 121 0 19 4 80 21 3 541 0 0 625 15 9 9 8210 60 70 NR NR NR 127 0 19 4 80 15 9 403 9 0 750 19 1 9 8210 60 70 NR NR NR 131 0 19 4 80 12 5 317 5 1 000 25 4 9 8210 60 70 NR...

Page 56: ...Aluminum SL100 Torch with Exposed Tip Starter Cartridge 9 8213 Electrode 9 8215 20A 9 8205 30A 9 8206 40A 9 8208 50 55A 9 8209 60A 9 8210 70A 9 8231 80A 9 8211 100A 9 8212 Tips Art A 04671 Shield Cap Deflector 9 8243 Ohmic Clip 9 8224 Shield Cup Body 9 8237 ...

Page 57: ... 250 6 4 9 8210 60 70 0 2 5 1 0 30 119 0 19 4 80 94 4 2398 0 375 9 5 9 8210 60 70 0 2 5 1 0 50 122 0 19 4 80 57 4 1458 0 500 12 7 9 8210 60 70 0 2 5 1 0 75 128 0 19 4 80 34 4 874 0 625 15 9 9 8210 60 70 NR NR NR 131 0 19 4 80 23 584 0 750 19 1 9 8210 60 70 NR NR NR 134 0 19 4 80 17 6 447 1 000 25 4 9 8210 60 70 NR NR NR 140 0 19 4 80 8 203 0 047 19 1 2 9 8211 80 65 0 2 5 1 0 00 101 0 19 4 80 419 1...

Page 58: ... Electrode 9 8215 Shield Cap Machine 40A 9 8245 20A 9 8205 30A 9 8206 40A 9 8208 Shield Cup Body 9 8237 50 55A 9 8209 60A 9 8210 70A 9 8231 80A 9 8211 90 100A 9 8212 Tip Tips Tips Shield Cup Body 9 8237 Shield Cup Body 9 8237 Shield Cap Machine 50 60A 9 8238 Shield Cap Machine 70 100A 9 8239 Art A 04672 Ohmic Clip 9 8224 ...

Page 59: ...50 119 0 19 4 80 34 863 6 0 500 12 70 9 8210 9 8238 60 70 1 88 4 8 0 75 121 0 19 4 80 23 4 594 36 0 625 15 88 9 8210 9 8238 60 70 NR NR NR 135 0 19 4 80 14 355 6 0 750 19 05 9 8210 9 8238 60 70 NR NR NR 130 0 19 4 80 13 6 345 44 1 000 25 40 9 8210 9 8238 60 70 NR NR NR 135 0 19 4 80 12 8 325 12 0 047 18 0 05 9 8211 9 8239 80 65 1 88 4 8 0 00 104 0 19 4 80 231 5867 4 0 120 11 0 13 9 8211 9 8239 80 ...

Page 60: ...213 Electrode 9 8215 Shield Cap Machine 40A 9 8245 20A 9 8205 30A 9 8206 40A 9 8208 Shield Cup Body 9 8237 50 55A 9 8209 60A 9 8210 70A 9 8231 80A 9 8211 90 100A 9 8212 Tip Tips Tips Shield Cup Body 9 8237 Shield Cup Body 9 8237 Shield Cap Machine 50 60A 9 8238 Shield Cap Machine 70 100A 9 8239 Art A 04672 Ohmic Clip 9 8224 ...

Page 61: ...75 1905 0 250 6 4 9 8210 9 8238 60 70 0 2 4 8 0 30 120 0 19 4 8 55 1397 0 375 9 5 9 8210 9 8238 60 70 0 2 4 8 0 50 122 0 19 4 8 28 711 2 0 500 12 7 9 8210 9 8238 60 70 0 2 4 8 0 75 128 0 19 4 8 17 431 8 0 625 15 9 9 8210 9 8238 60 70 NR NR NR 135 0 19 4 8 13 330 2 0 750 19 1 9 8210 9 8238 60 70 NR NR NR 139 0 19 4 8 10 254 1 000 25 4 9 8210 9 8238 60 70 NR NR NR 142 0 19 4 8 4 101 6 0 052 18 0 0 9...

Page 62: ...Electrode 9 8215 Shield Cap Machine 40A 9 8245 20A 9 8205 30A 9 8206 40A 9 8208 Shield Cup Body 9 8237 50 55A 9 8209 60A 9 8210 70A 9 8231 80A 9 8211 90 100A 9 8212 Tip Tips Tips Shield Cup Body 9 8237 Shield Cup Body 9 8237 Shield Cap Machine 50 60A 9 8238 Shield Cap Machine 70 100A 9 8239 Art A 04672 Ohmic Clip 9 8224 ...

Page 63: ...0 0 2 4 8 0 30 126 0 19 4 8 76 1930 4 0 375 9 5 9 8210 9 8238 60 70 0 2 4 8 0 50 129 0 19 4 8 46 1168 4 0 500 12 7 9 8210 9 8238 60 70 0 2 4 8 0 75 136 0 19 4 8 28 711 2 0 625 15 9 9 8210 9 8238 60 70 NR NR NR 139 0 19 4 8 19 482 6 0 750 19 1 9 8210 9 8238 60 70 NR NR NR 142 0 19 4 8 14 355 6 1 000 25 4 9 8210 9 8238 60 70 NR NR NR 150 0 19 4 8 4 101 6 0 047 18 0 0 9 8211 9 8239 80 65 0 2 4 8 0 00...

Page 64: ...8243 4 15 Operator s Custom Cutting Speed Charts Torch Tip Shield Cap Current Plasma Press Pierce Time Arc voltage In GA mm Cat Cat Amps PSI In mm SEC Volts in mm IPM mm min Material Torch SL100 with Shielded Tip Power Supply CutMaster 151 Automated Table Dry Gas Compressed Air Recommended Travel Speed Stand off Height Pierce Height Material thickness ...

Page 65: ...hield Cap Deflector 9 8243 Torch Tip Shield Cap Current Plasma Press Pierce Time Arc voltage In GA mm Cat Cat Amps PSI In mm SEC Volts in mm IPM mm min Material Torch SL100 with Shielded Tip Power Supply CutMaster 151 Automated Table Dry Gas Compressed Air Recommended Travel Speed Stand off Height Pierce Height Material thickness ...

Page 66: ...hield Cap Deflector 9 8243 Torch Tip Shield Cap Current Plasma Press Pierce Time Arc voltage In GA mm Cat Cat Amps PSI In mm SEC Volts in mm IPM mm min Material Torch SL100 with Shielded Tip Power Supply CutMaster 151 Automated Table Dry Gas Compressed Air Recommended Travel Speed Stand off Height Pierce Height Material thickness ...

Page 67: ...hield Cap Deflector 9 8243 Torch Tip Shield Cap Current Plasma Press Pierce Time Arc voltage In GA mm Cat Cat Amps PSI In mm SEC Volts in mm IPM mm min Material Torch SL100 with Shielded Tip Power Supply CutMaster 151 Automated Table Dry Gas Compressed Air Recommended Travel Speed Stand off Height Pierce Height Material thickness ...

Page 68: ...OPERATION 4 30 Manual 0 4691 4 This Page Left Blank ...

Page 69: ...r Filter Assembly Thefilterelementwillbevisibleandstillattachedto themainbodyoftheRegulator Filter 3 GraspthefilterelementandunscrewitfromtheRegulator Filterbody Thefilterelementwillcomeoffwithaspooland someadditionalpieces 4 Notethecorrectassemblyofthefilter spoolthenremovethe filterfromthespoolandeithercleanitorreplaceit 5 Thefilterelementandspool withthebaffle ringinplace teethfacingdownward ca...

Page 70: ...ing FiltertochangeFilterElement 3 Disconnectgassupplyhose 4 Turn the Cover counter clockwise and remove it from the Filter Housing The Filter Element is located inside the Housing Art A 02476 Filter Element Cat No 9 7741 Housing Cover Barbed Fitting Spring Assembled Filter O ring Cat No 9 7743 Single StageFilterElementReplacement 5 RemovetheFilterElementfromtheHousingandsetElementasidetodry 6 Wipe...

Page 71: ...ng the Filter Assembly as injury could result 3 LoosenthetwoboltsonthetopoftheFilterAssemblyenoughtoallowtheFilterElementstomovefreely 4 NotethelocationandorientationoftheoldFilterElements 5 SlideouttheoldFilterElements First Second Stage Cartridges as marked Art A 02942 OptionalTwo StageFilterReplacement 6 SlidethereplacementFilterElementsintotheFilterAssembly withthesameorientationasnotedinStep4...

Page 72: ...ughwithcompressedair CAUTION Dry the torch thoroughly before reinstalling E O Ring Lubrication AnO ringontheTorchATCMaleConnectorrequireslubricationonaregularbasis dependingonhowfrequentlythetorch isdisconnectedandre connected ThiswillallowtheO ringtoremainpliableandprovideaproperseal TheO ringwilldry out becominghardandcracked iftheO ringlubricantisnotusedonaregularbasis Thiscanleadtoperformancep...

Page 73: ...e Worn torch parts f Non Genuine Thermal Dynamics parts used 3 ExcessiveDrossFormation 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 f Incorrect gas pressure 4 ShortTorchPartsLife a Oil or moisture in air source b Exceeding system capability material too thick c Excessive pilot arc time d Ga...

Page 74: ...easiest listed first then remedies Repair as needed being sure to verify that unit operatesproperlyafteranyrepairs C Common Symptoms A ACindicator OFF 1 Switch at main power panel in OFF open position a Closemainpowerswitch 2 Power Supply ON OFF switch in OFF down position a TurnswitchtoON up 3 Torch is not connected properly to Power Supply a TurnpowersupplyON OFFswitchtoOFF down Checktorchconnec...

Page 75: ...indicator ON GAS indicator OFF 1 Gas not connected a Checkgasconnections 2 Gas pressure too low for power supply operation a Adjustpressureto70 75psi 4 8 5 2bar E Torchwillnotpilot gasflows ACindicator ON GAS TEMP andDC indicatorsOFF 1 Gas pressure is below power supply minimum requirement a Adjustpressureto70 75psi 4 8 5 2bar NOTE Minimum pressure for power supply operation is lower than minimum ...

Page 76: ...tempt to over tighten the shield cup as irreparable damage to internal components may result 3 Upper O ring on torch head is in wrong position a Removeshieldcupfromtorch checkpositionofupperO ring Correctifnecessary Upper Groove with Vent Holes Must Remain Open Threads Upper O Ring in Correct Groove Lower O Ring Art A 03725 H Torchwillnotpilot AC GAS andTEMP indicators ON DC indicatorOFF 1 Air flo...

Page 77: ...witch to ON up position J Gascycleson andoffwithouttorchswitchbeingactivated ACindicator Flashing Gasindicator ON DC indicator OFF 1 Torch tip or electrode missing a Shutoffpowersupply Removeshieldcup installmissingpart s TurnpowersupplyON OFFswitchtoON up 2 Startcartridgestuckorworn a Removethestartcartridge Checkforexcessivewear pluggedgasholes ordiscoloration Checkthelowerendfitting for free mo...

Page 78: ... 6 Fluctuations in input power a Haveelectriciancheckinputlinevoltage M Arcshutsoffduringoperation arcwillnotrestartwhentorchswitchisactivated 1 Power Supply is overheated TEMP indicator ON a Letunitcooldownforatleast5minutes MakesuretheunithasnotbeenoperatedbeyondDutyCyclelimit Refer toSection2fordutycyclespecifications 2 Fan blades blocked TEMP indicator ON a Checkandclearblades 3 Air flow obstr...

Page 79: ...embliesofthisunit Evidence ofunauthorizedrepairswillvoidthefactorywarranty NOTE Follow all instructions as listed and complete each in the order presented B How to Use the Troubleshooting Guide ThefollowinginformationisaguidetohelptheServiceTechniciandeterminethemostlikelycausesforvarioussymptoms This guideissetupinthefollowingmanner 1 Performoperationalcheck s ontheequipmenttoisolateproblemtoposs...

Page 80: ...ote thesymptomandproceedtoSubsection5 05 MainInputandInternalPowerProblems D Pilot Arc Test 1 Activatethetorch toestablishapilotarcandnotethefollowing Gasflows Preflowdelay twoseconds thenDCindicatorturnsON Pilotarcisestablished ThiscompletesthePilotArcTest Iftheaboveareallcorrectthenproceedtoparagraph E Iftheunitdoesnotfunctionproperly thennotethesymptomandproceedtoSubsection5 06 PilotArcProblems...

Page 81: ... disassembling the Power Supply torch parts or torch and leads assemblies 1 Removethe upperscrewssecuringthecovertothemainassembly 2 Loosen butdonotremove thelowerscrews NOTE There is a ground wire attached from the cover to the main body of the unit 3 Carefullyliftthecoverofftheunit andremovethenutsecuringthegroundwiretothesidepanel 4 Re installthecoverbyreversingtheabovesteps Art A 04510 Lower s...

Page 82: ...ely after the ON OFF Switch is turned on 1 Faulty Input Diode a TestInputDiodeperSubsection5 08 C repairasnecessary C Fans do not operate AC indicator OFF 1 Front Panel ON OFF switch in OFF position a Place switch to ON up position 2 Main power disconnect open a Close main power disconnect 3 Torch is not properly connected to Power Supply a ChecktorchconnectionstoPowerSupply Tightenoradjustasneede...

Page 83: ...ntedCircuitBoardLayout logicboardnotshown 6 Improper input power cable connections inside Power Supply a RefertoSystemSchematicandcorrectifneeded 7 Defective input power cable a Replaceinputpowercable Refertosubsection5 09 L 8 Fuse blown inside Power Supply a ReplaceinternalFuseperSubsection5 09 C 9 Line voltage above 10 tolerance over voltage protection a Reduce line supply 10 Faulty Auxiliary Tr...

Page 84: ...4 Faulty Temperature Sensor Switch a Check IGBT Heatsink Temp Sensor TS1 Disconnect wire connector P29 from terminal J29 on Main PC Board Check connector pins 1 and 2 for 10K ohm 25 at ambient temperature If resistance is not 10K ohm 25 replace TS1 b Check Inductor Temp Switch TS2 Disconnect wire connector P32 from terminal J32 on Main PC Board Check connector pins 1 and 2 for at least 12K ohms If...

Page 85: ...present replacetheLogicPCBoard 3 Faulty Wiring or Faulty Logic PC Board Checkfor12vdc atMainPCBoardpinJ24 3toJ24 4fromtheLogicPCBoard RefertoAppendix Pages MainPCBoard Layout Iflessthanavolt replaceLogicPCBoard G GascontinuestoflowwithRUN RAPIDAUTORESTART SETswitchinRUNposition 1 Damaged gas solenoid a TurnthefrontpanelON OFFswitchtoOFF Ifgascontinuestoflow debrisfromtheairlineispreventingthesolen...

Page 86: ...3 TP9 TP4 TP10 TP5 TP11 TP6 D33 D13 D25 LogicBoardLayout H Gasflowscontinuouslywhenpoweristurnedon ACindicator flashes 1 Torch switch is activated closed before user turns power on a Release torch switch 2 Faulty torch switch a Check torch switch for continuity ...

Page 87: ...d Cylinder at Full Compression Spring Loaded Cylinder at Full Extension 1 8 3 mm 5 06 Pilot Arc Problems WARNING The following tests must be performed with the power supply connected to primary input power There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair without proper training in power electronics measurement and troubleshooting ...

Page 88: ...25 C Torchwillnotpilot AC GAS and TEMPindicators ON 1 Air flow blocked a Checkforblockedairflowaroundtheunitandcorrectcondition 2 Unit is overheated a Letunitcooldownforatleast5minutes MakesuretheunithasnotbeenoperatedbeyondDutyCyclelimit Refer todutycycledatainSpecificationsSection 3 Input line voltage is low a Checkandconnecttoproperinputpowerline 4 Faulty Temperature Sensor Switch a RefertoAppe...

Page 89: ... M2 D Torchwillnotpilotwhentorchswitchisactivated AC andGAS indicatorsON Temp and DC indicatorsOFF 1 Gas pressure too high or too low a Adjustgaspressureperpressuresettinglabelonpowersupply 2 Torch tip start cartridge or electrode missing a Turnoffpowersupply Removeshieldcup installmissingparts 3 Start cartridge is stuck a Turnoffpowersupply Removeshieldcup tip andstartcartridge Checklowerendfitti...

Page 90: ...hefollowingpointsontheIGBTs IGBT A E4toE10 E10toE20 IGBT B E23toE27 E27toE30 Voltage should be approximately 20 vdc before the start signal is active If voltage measures greater than 100 vdc when the start signal is active replace the respective IGBT s E2 E3 E1 Secondary Transformer 32 27 Input Diode mounts to center chassis E1 E3 E2 Fuse LT1 E33 J25 E10 E20 E7 E15 E30 E27 E32 J26 E23 J23 J24 J34 ...

Page 91: ... 5 Faulty torch a Checktorch 6 Faulty connection of wire 58 or 62 to Pilot Board a Checkwiringconnection RefertotheSystemSchematicintheAppendix Connectionsshouldbe Wire 58toPilotBoardterminalE58 Wire 62toPilotBoardterminalE62 Ifwires58and62arenotconnectedtotheproperterminals replacethePilotBoard 7 Faulty Main PC Board a Checkforapproximately12vdc atTP4toTP1 Iflessthan2vdc replacetheMainPCBoard 8 F...

Page 92: ... components in torch and leads assembly a Inspecttorchassembliesandreplaceifnecessary C Limitedoutputwithnocontrol 1 Poor input or output connections to power supply a Checkallinputandoutputconnections 2 Faulty components in torch and leads assembly a Inspecttorchassembliesandreplaceifnecessary D Erraticorimpropercuttingoutput 1 Poor input or output connections to power supply a Checkallinputandou...

Page 93: ...CheckperSubsection5 14 D B When operating the amperage drops off after the main cutting arc starts 1 Torch tip contacts workpiece Raisethetorchtipoffthework Atoutputsettingsover40amps circuitryinthepowersupplyautomaticallyreduces outputcurrentto40ampsifthetorchtipcontactstheworkpiece 2 FaultyPilotBoard a WithpoweroffandwiresE58andE62disconnectedfromthepilotboard measureforcontinuitybetweenterminal...

Page 94: ...sidethehandle thenliftthebaseoftheunitawayfromthe TubeHandle 4 Witharubbermallet separatethetwohandleendsasshownbelow 5 InstallthereplacementTubeHandlebyreversingtheabovesteps 6 Reinstallthepowersupplycover Art A 02847 C Cover Installation 1 Reconnectthegroundwire ifnecessary 2 Placethecoverontothepowersupply sothatslotsinthebottomedgesofthecoverengagethelowerscrews 3 Tightenlowerscrews 4 Reinstal...

Page 95: ...eKnob 3 PlacethereplacementKnobonthepotentiometershaftwiththelocationofthepointerthesameasnotedinstep1 4 Tightenthescrewtosecuretheknobtothepotentiometershaft B ON OFF Switch SW1 Replacement 1 RemovethepowersupplycoverperSection5 09 A 2 DisconnectthewiresontherearoftheON OFFSwitch Notethelocationofeachwire asshownbelow Art A 02774 Wire 21 Wire 24 Top clip Wire 22 Wire 23 3 Squeezetogethertheclipso...

Page 96: ...3 SqueezetogethertheclipsonthetopandbottomoftheSwitch thenremovetheswitchthroughtheFrontPanel 4 InstallthereplacementSwitchbyreversingtheabovesteps 5 Reinstallthepowersupplycover D POT LED PC Board Replacement 1 RemovethepowersupplycoverperSection5 09 A 2 RemoveCurrentKnob 3 DisconnectwireharnessConnectorfromPOT LEDPCBoard 4 RemovePCBoardfromstandoffs 5 InstallthereplacementPOT LEDPCBoardbyreversi...

Page 97: ...RemovethepowersupplycoverperSection5 09 A 2 Locatetheinternalfuseontheleftsideofthecenterchassis 3 Replacethefuse Areplacementfuseislocatedinsidethepowersupply RefertoSection6 PartsLists forreplacement fusecatalognumber 4 Reinstallthepowersupplycover Art A 03002 Fuse Location InternalFuseLocation ...

Page 98: ...herowofconnectorslabeledLtowardtherearofthePowerSupply Fasteninplacewiththehardwareremovedpreviously 7 Completethewiringconnectionsasshown NOTE It is important that wires are installed correctly as shown to prevent damage to the unit 8 Reinstallthepowersupplycover Art A 03194 Main Contactor 13 5 L 1 L 2 L 3 T 1 T 2 T 3 To E3 Connections to Main PCB 4 12 To E1 To E2 Input Side L1 L3 L2 Art A 03212 ...

Page 99: ...replacement component to prevent damage to the component Thermal pads heatsinks and the large flat surface on the back of diodes and IGBTs must be kept clean Diodes and IGBTs must not be bent or allowed to pick up any foreign material A very clean installation between the module and the heatsink or chassis is essential for proper operation 1 RemovethepowersupplycoverperSection5 09 A 2 TurnthePower...

Page 100: ...ge or failure 8 Installreplacementcomponentsasfollows a Applythethermalpadtotheflatsurfaceofthebridge Alignthepadwiththerectangularflatsurfaceonthebackof thedevice b Alignthebridgewithitsmountingholesinthepowersupplychassis c Securethebridgeandrectangularpadtothechassiswiththereplacementscrewsandwashers Bridge Thermal Pad Art A 04609 Power Supply Center Chassis InputDiodeReplacement 9 Torquethedio...

Page 101: ...Diode mounts to center chassis E2 E3 E1 To Input Contactor Copper Strap 78 1 Input Diode mounts to center chassis E2 E3 E1 To Input Contactor 208 230V Units 460V Art A 04610 1 2 3 1 2 3 Power Supply Main PC Board Power Supply Main PC Board 2 3 1 400V 600V 415V Units 11 Torquethescrewssecuringthewirestothebridgeto22in lbs 2 5Nm NOTE Failure to torque properly will cause component damage ...

Page 102: ...propyl alcohol and a clean rag to clean the heat sink area behind the component being replaced Clean the large flat surface on the back of the replacement component Do not scratch or abrade the surface CAUTION The component mounting area and the mounting surface of the IGBT module must be free of debris pits scratches or other imperfections which could make the component lift off the mounting surf...

Page 103: ...hat the washers are under the heads of the screws Art A 04643 IGBT PC Boards IGBT Modules 10 Torquescrew s to22 in lb 2 5Nm NOTE Failure to torque properly will cause component damage 11 Connectwirespertheillustration Art A 04644 Main PC Board IGBT PC Boards IGBT Modules 12 Standtheunitupright reinstallthecover ...

Page 104: ...heAppendixpagesifnecessary 5 RemovethetwolongTransformerscrewssecuringtheAuxiliaryTransformertotheCenterChassis 6 RemovetheotherscrewssecuringthePCBoardtotheCenterChassis 7 CarefullyremovetheoriginalPCBoard 8 InstallthereplacementPCBoardbyreversingstepsabove ItmaybeeasiertoinstallthePCBoardifthePowerSupply isturnedonitsrightsidefirst Torquethescrewsto17inch pounds 1 9Nm E2 E3 E1 Secondary Transfor...

Page 105: ... Cable Strain Relief on the inside of the Rear Panel and remove the Input Power Cable from the unit 4 InstallthereplacementInputPowerCablebyreversingthe abovesteps TheInputPowerCablegroundwirerequiresa ringterminal G EMI Filter Replacement CE Units Only 1 RemovethepowersupplycoverperSection5 09 A 2 Labeltheinputpowercableconnectionsandthecableconnectionstothemaininputcontactor 3 Disconnectallwirea...

Page 106: ...ided they are opposite each other For grounding purposes one of those screws must be installed with a star washer b PlacetheFanAssemblyPanelinpositioninthePowerSupply 1 TheinneredgeofthePanelhastabsthatengageslotsinthecenterchassis Ensurethatthesetabsfullyengage inthechassis 2 PressthePaneldownward PressthebottomflangefullyagainstthebottompanelofthePowerSupply 3 Ensurethattheholeinthebottomflangeo...

Page 107: ...untstothePowerSupplycenterchassis RefertoPilotBoardLayoutintheAppendix 1 RemovethepowersupplycoverperSection5 09 A 2 LabelanddisconnectwiresfromPilotPCBoardterminalsE58andE62 DisconnectthewireharnessfromreceptacleJ28 3 RemovethehardwaresecuringthePilotPCBoardtothepowersupplycenterchassis RemovethePilotPCBoard 4 PositionthereplacementPilotPCBoardagainstthestandoffsfastenedtothecenterchassis Notetha...

Page 108: ...islodgetheAssembly fromunderneaththecliponthetopoftheHeatsinkShroud Heatsink Shroud Dislodge Solenoid Assembly Push Clip to the left to release Solenoid Assembly Art A 03705 2 3 1 4 ReleasethehosefromtheAdapterFittingontheinputsideoftheSolenoidAssembly Holdawrenchorsimilartool againstthelockingringontheFitting thenpullonthehosetoreleaseit 5 ReleasethehosefromtheAdapterFittingontheoutputsideoftheSo...

Page 109: ...lcoholandacleanragtocleantheheatsink Donotscratchorabradetheheatsink 6 ApplythethermalpadprovidedwiththereplacementPCBtotheheatsink Secureinplacewithsmallpiecesofmasking tape Thetapemustcovernomorethan1 4 6mm oftheedgeofthethermalpad Output PC Board Thermal Pads Output Diodes Art A 04639 Heatsink 7 Useisopropylalcoholtocleanthelargeflatsurfaceonthebackofthecomponent 8 Securereplacementboardasfollo...

Page 110: ...ear edgeoftheHeatsinkShroud 5 RemovetheFanAssemblypersubsection5 08C 6 LabelanddisconnectthewiresconnectedtothePilotPCBoard 7 RemovethehardwaresecuringthePilotPCBoardinplace PullthePCBoardoffthecenterchassis 8 LabelanddisconnectwiresNo 45 47 49 and52fromthePowerOutputPCBoard 9 DisconnectthewiresfromtheOutputInductortoterminalE43onthePowerOutputPCBoard Disconnectthetorchreceptaclegroundwireconnecte...

Page 111: ...downwardtolockitintoposition c Checkforproperinstallation thetransformershouldremainsecurelyinplace 6 Passwires 27and32throughtheholeinthecenterofthemainchassis Connectwire 27toterminalE27andwire 32 toterminalE32ontheMainPowerPCBoard 7 Reinstall theHeatsinkShroudAssemblypersub sectionH H Output Inductor Assembly Removal and Replacement 1 DisengagetheHeatsinkShroudperparagraphE 2 Disconnectthewires...

Page 112: ...ethattherubberfeetontheMainTransformerengageholesintheShroud d Put hex nuts on the studs Tighten the nuts on the right rear top and bottom studs Leave the nuts on the left forward studsloosetemporarily 4 PuttheFanAssemblyinplacepersubsection 5 12 A ReconnecttheworkcabletoterminalE61onthePowerOutput PCBoard 5 TightenthenutssecuringtheleftedgeoftheHeatsinkShroudAssembly Thestudandnutonthebottomlefte...

Page 113: ...by the catalog number shown B Returns If a product must be returned for service contact your distributor Materials returned without proper authorization will not be accepted 6 02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly as listed in the parts list for each type item Also include the model and serial number of the power supply A...

Page 114: ... ReplacementFilterHose notshown 9 7742 2 ReplacementFilterElement 9 7741 1 PowerSupplyDustCover 9 7072 1 ExtendedWorkCable 50ft 15 2m withClamp 9 8350 1 Multi PurposeCart 7 8888 1 25 7 6mCNCInterfaceCable 9 8312 1 50 15 2mCNCInterfaceCable 9 8313 1 75 22 8mCNCInterfaceCable 9 8315 1 100 30 4mCNCInterfaceCable 9 8316 1 125 38 0mCNCInterfaceCable 9 8317 Art A 02476 Filter Element Cat No 9 7741 Housi...

Page 115: ...y Major External Replacement Parts Item Qty Description Catalog 1 1 Coverwithlabels 9 8335 2 RearPanel providedatataginformationwhenordering 1 For208 230 VoltPowerSupplies 9 8668 1 For 400 Volt 415V 460 Volt and 600 Volt Power Supplies 9 8322 3 1 Tube roll handle 9 7998 Art A 03709 3 3 1 2 ...

Page 116: ...f 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 9 1042 4 1 Assembly Pot LED PC Board 9 8004 for RoHS 9 0045 5 1 Work Cable 4 AWG with Clamp 20 Ft 6 1 m 9 8336 NOTE Illustrationmayvary slightly from unit Art A 04541 1 2 3 4 5 ...

Page 117: ...1 RegulatorMountingBracket 9 7589 4 InputPowerCable 1 for 208 230 Volt Units 9 8596 1 for 208 230 Volt CSA Units 9 8665 1 for 400 Volt Three Phase units 9 8562 1 for 400 Volt 415 Volt CE units 9 8553 1 for 460 Volt Three Phase units and 600 Volt Three Phase units 9 8593 5 1 Mounting Nut 9 5804 6 1 Pressure Gauge 9 1045 NOTE Illustrationmayvaryslightlyfromunit Art A 03005 2 1 3 4 5 6 ...

Page 118: ...t Power Supplies 9 8554 3 1 Connector PCB 9 8576 for RoHS 9 0051 4 1 PC Board Assembly Logic 9 8338 for RoHS 9 0071 5 1 PC Board Assembly Kit IGBT Circuit for 208 230V 400V 9 8334 415 Volt and 460V units for RoHS 9 0053 5 1 PC Board Assembly Kit IGBT Circuit for 600V units 9 8666 1 IGBT Diode 1 IGBTPCB 1 ThermalPad 6 1 InputDiodeKit 9 8030 7 1 PCBoard Assembly MainPower for208 230 VoltPowerSupplie...

Page 119: ...Manual 0 4691 6 7 PARTS LISTS 6 NOTE Illustration may vary slightly from unit 3 5 4 1 7 Art A 04514 6 2 2A OR 8 5 ...

Page 120: ...Volt units 9 8345 for 400 Volt 415 Volt units 9 8347 for 460 Volt units 9 8346 for 600 Volt units 9 8348 5 1 Assembly Output Inductor L1 9 8591 6 1 Assembly Output Power PCB 9 8339 for RoHS 9 0078 7 Assembly Output Diode PC Board Kit 9 8349 1 Output Diode Assembly 1 Thermal Pad for RoHS 9 0050 8 1 Automation Interface PC Board 9 4894 9 1 Automation Interface Wire Harness 9 4895 10 1 Transformer on...

Page 121: ...691 6 9 PARTS LISTS 6 NOTE Illustrationmayvary slightly from unit 2 3 5 1 4 6 Art A 07121 Work Cable Output Diode Heatsink IGBT Heatsink Heatsink Shroud Fan Shroud 3 8 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 9 7 7 7 7 10 ...

Page 122: ...7864 1 50 foot 15 2mLeadsAssemblywithATCconnector 4 7853 7 1 11 279mmRack 9 7041 8 1 11 279mmMountingTube 9 7043 9 1 EndCapAssembly 9 7044 10 2 Body Mounting PinchBlock 9 4513 11 1 Pin Mounting Pinch Block 9 4521 12 1 Torch Holder Sleeve 7 2896 13 1 Pinion Assembly does not include positioning tube 7 2827 14 1 Torch Holder Sleeve 7 2896 15 1 Pinion Gear Short 8 6074 16 1 Handwheel Torch Holder 9 4...

Page 123: ...Manual 0 4691 6 11 PARTS LISTS 6 Art A 03872 6 1 4 2 3 5 8 9 10 12 11 7 10 22 19 15 14 16 17 18 20 21 21 13 ...

Page 124: ...60 7 1 Rack 9 9448 8 1 Mounting Tube 9 9445 9 1 End Cap Assembly 9 7044 10 2 Body Mounting Pinch Block 9 4513 11 1 Pin Mounting Pinch Block 9 4521 12 1 Torch Holder Sleeve 7 2896 13 1 Pinion Assembly does not include positioning tube 7 2827 14 1 Torch Holder Sleeve 7 2896 15 1 Pinion Gear Short 8 6074 16 1 Handwheel Torch Holder 9 4514 17 1 Low Profile Torch Holder 1 3 8 Dia w o Hardware 9 4515 18...

Page 125: ...Manual 0 4691 6 13 PARTS LISTS 6 Art A 07113 6 1 4 2 3 5 8 10 12 11 7 10 22 19 15 14 16 17 18 20 21 21 13 9 24 23 ...

Page 126: ...p Kit Cat No 5 0079 80 Amp Kit Cat No 5 0122 100 Amp Kit Cat No 5 0174 Electrode 9 8215 3 3 3 3 30A Standoff Tip 9 8206 5 5 5 5 40A Standoff Tip 9 8208 5 5 5 5 60A Standoff Tip 9 8210 5 5 5 80A Standoff Tip 9 8211 5 5 100A Standoff Tip 9 8212 5 Shield Cup Body 9 8237 1 1 1 1 Shield Cap Deflector 9 8243 1 1 1 1 Shield Cap Machine 40A 9 8245 1 1 1 1 Shield Cap Machine 60A 9 8238 1 1 1 Shield Cap Mac...

Page 127: ...9 8215 Shield Cap Machine 40A 9 8245 20A 9 8205 30A 9 8206 40A 9 8208 Shield Cup Body 9 8237 50 55A 9 8209 60A 9 8210 70A 9 8231 80A 9 8211 90 100A 9 8212 Tip Tips Tips Shield Cap Machine 50 60A 9 8238 Shield Cap Machine 70 100A 9 8239 Art A 04603 Ohmic Clip 9 8224 Shield Cap Deflector 9 8243 ...

Page 128: ...hine Torch and 35 foot 10 6 m Leads with ATC Connector 7 5232 1 SL100 Machine Torch and 50 foot 15 2 m Leads with ATC Connector 7 5216 100 Amp Machine Torch and Leads Assemblies Unshielded Leads with Solenoid 1 SL100SV Machine Torch and 25 foot 7 6 m Leads with ATC Connector 7 4001 1 SL100SV Machine Torch and 35 foot 10 6 m Leads with ATC Connector 7 4002 1 SL100SV Machine Torch and 50 foot 15 2 m...

Page 129: ...nsed 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 Shield Cap Machine 70 100A 9 8244 Shield Cap Drag 40A 9 8245 Shield Cap Machine 40A ...

Page 130: ...PARTS LISTS 6 18 Manual 0 4691 6 This Page Left Blank ...

Page 131: ...stem 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 Restart for gouging trimming or expanded metal applications RESULT Gas flow stops ACTION Release torch trigger RESULT Main arc stops Gas flow stops after post flow ACTION ON OFF switch to OFF RESULT All i...

Page 132: ...ined under the power supply manufacturer s test procedures Second row Rated cutting current values Third row Conventional load voltage values 4 Sections of the Data Tag may be applied to separate areas of the power supply I Art A 03288 Date of Mfr Output Range Amperage Voltage Type of Power Supply Note 1 Output Current Type Rated No Load Voltage Plasma Cutting Symbol Manufacturer s Name and or Log...

Page 133: ...y supply and pressure flow 4 Purge plasma gas line to remove any moisture build up 5 Inspect input power cable for damage or exposed wires replace if necessary Weekly or Every 30 Cutting Hours 1 Check fan for proper operation and adequate air flow 2 Blow or vacuum dust and dirt out of the entire machine CAUTION Do not blow air into the power supply during cleaning Blowing air into the unit can cau...

Page 134: ... 5 6 7 8 3 Open 2 Orange PIP 1 Black PIP 4 Open 2 PIP Circuit 1 PIP Circuit 3 Not Used 4 Not Used 6 Open Art A 03900 ATC Female Receptacle Front View ATC Male Connector Front View Negative Plasma Pilot Negative Plasma 6 Open 7 Torch Solenoid 5 Torch Solenoid 8 Open 8 Open 5 White Torch Solenoid 7 Green Torch Solenoid 5 6 7 8 1 2 3 4 Pilot 1 2 3 4 5 6 7 8 3 Open 2 Orange PIP 1 Black PIP 4 Open 2 PI...

Page 135: ...ocket No s 1 2 5 4 3 7 6 8 Torch Leads Torch Head No Signal 1 2 5 4 3 7 6 8 Automated CutMaster Power Supply with ATC Torch Receptacle Automated SL100SV Torch w Solenoid on Positioning Tube Torch Lead with ATC Connector Power Supply PIP Switch ATC Male Torch Leads Connector ATC Female Torch Receptacle Negative Plasma Lead Pilot Lead Art A 07115 Pin No s Socket No s 1 2 5 4 3 7 6 8 Main PC Board 1 ...

Page 136: ...ve 6 Blue Positive SC 11 Controller 7 Yellow Arc Volts Negative 11 Gray 10 Violet Alignment Splines 5 Orange Negative SC 11 Controller 4 Green Torch Switch 8 Logic Common 9 Brown Arc Volts Positive Alignment Splines Art A 03993 2 White 13 Open 14 White Red OK to Move Alignment Spline 3 Red Torch Switch ...

Page 137: ...1 0 0 0 1 3 3 6 6 30 1 1 1 0 0 0 0 0 0 2 5 5 0 40 1 1 1 1 1 1 1 1 1 2 0 4 0 50 1 0 DOWN OFF 1 UP ON SW 4 SW3 SW2 SW1 Volts Out for 100vdc In Volts Out for 200vdc In Division Factor Factory Default Settings Suitable for Thermal Dynamics SC 11 Standoff Control Other Common Settings 0 DOWN OFF 1 UP ON Automation Interface Switch Setting Chart Common Voltage Divider Output Settings ...

Page 138: ... 0 19 69 0 0 0 1 0 1 0 1 19 83 0 0 0 1 0 1 1 0 19 97 0 0 0 1 0 1 1 1 20 11 0 0 0 1 1 0 0 0 20 29 0 0 0 1 1 0 0 1 20 44 0 0 0 1 1 0 1 0 20 58 0 0 0 1 1 0 1 1 20 72 0 0 0 1 1 1 0 0 20 87 0 0 0 1 1 1 0 1 21 01 0 0 0 1 1 1 1 0 21 15 0 0 0 1 1 1 1 1 21 30 0 0 1 0 0 0 0 0 21 67 0 0 1 0 0 0 0 1 21 81 0 0 1 0 0 0 1 0 21 95 0 0 1 0 0 0 1 1 22 09 0 0 1 0 0 1 0 0 22 25 0 0 1 0 0 1 0 1 22 39 0 0 1 0 0 1 1 0 2...

Page 139: ... 25 98 0 0 1 1 1 1 0 1 26 12 0 0 1 1 1 1 1 0 26 26 0 0 1 1 1 1 1 1 26 41 0 1 0 0 0 0 0 0 27 32 0 1 0 0 0 0 0 1 27 46 0 1 0 0 0 0 1 0 27 60 0 1 0 0 0 0 1 1 27 74 0 1 0 0 0 1 0 0 27 89 0 1 0 0 0 1 0 1 28 04 0 1 0 0 0 1 1 0 28 18 0 1 0 0 0 1 1 1 28 32 0 1 0 0 1 0 0 0 28 50 0 1 0 0 1 0 0 1 28 65 0 1 0 0 1 0 1 0 28 78 0 1 0 0 1 0 1 1 28 93 0 1 0 0 1 1 0 0 29 08 0 1 0 0 1 1 0 1 29 22 1 0 0 0 0 0 0 0 29 ...

Page 140: ...1 30 87 1 0 0 0 1 0 1 1 30 92 0 1 0 1 1 0 0 0 31 05 1 0 0 0 1 1 0 0 31 07 0 1 0 1 1 0 0 1 31 20 1 0 0 0 1 1 0 1 31 21 0 1 0 1 1 0 1 0 31 33 1 0 0 0 1 1 1 0 31 35 0 1 0 1 1 0 1 1 31 48 1 0 0 0 1 1 1 1 31 50 0 1 0 1 1 1 0 0 31 63 0 1 0 1 1 1 0 1 31 77 1 0 0 1 0 0 0 0 31 86 0 1 0 1 1 1 1 0 31 91 1 0 0 1 0 0 0 1 32 00 0 1 0 1 1 1 1 1 32 05 1 0 0 1 0 0 1 0 32 14 1 0 0 1 0 0 1 1 32 28 0 1 1 0 0 0 0 0 32...

Page 141: ... 0 1 1 1 1 0 33 90 0 1 1 0 1 0 1 1 34 04 1 0 0 1 1 1 1 1 34 05 0 1 1 0 1 1 0 0 34 19 0 1 1 0 1 1 0 1 34 33 1 0 1 0 0 0 0 0 34 42 0 1 1 0 1 1 1 0 34 47 1 0 1 0 0 0 0 1 34 56 0 1 1 0 1 1 1 1 34 61 1 0 1 0 0 0 1 0 34 70 1 0 1 0 0 0 1 1 34 84 0 1 1 1 0 0 0 0 34 98 1 0 1 0 0 1 0 0 35 00 0 1 1 1 0 0 0 1 35 12 1 0 1 0 0 1 0 1 35 14 0 1 1 1 0 0 1 0 35 26 1 0 1 0 0 1 1 0 35 28 0 1 1 1 0 0 1 1 35 40 1 0 1 0...

Page 142: ...0 37 55 1 0 1 1 0 1 0 1 37 69 1 0 1 1 0 1 1 0 37 83 1 0 1 1 0 1 1 1 37 97 1 0 1 1 1 0 0 0 38 15 1 0 1 1 1 0 0 1 38 30 1 0 1 1 1 0 1 0 38 44 1 0 1 1 1 0 1 1 38 58 1 0 1 1 1 1 0 0 38 73 1 0 1 1 1 1 0 1 38 87 1 0 1 1 1 1 1 0 39 01 1 0 1 1 1 1 1 1 39 16 1 1 0 0 0 0 0 0 40 07 1 1 0 0 0 0 0 1 40 21 1 1 0 0 0 0 1 0 40 35 1 1 0 0 0 0 1 1 40 49 1 1 0 0 0 1 0 0 40 64 1 1 0 0 0 1 0 1 40 79 1 1 0 0 0 1 1 0 40...

Page 143: ... 1 0 0 0 1 1 45 60 1 1 1 0 0 1 0 0 45 76 1 1 1 0 0 1 0 1 45 90 1 1 1 0 0 1 1 0 46 04 1 1 1 0 0 1 1 1 46 18 1 1 1 0 1 0 0 0 46 36 1 1 1 0 1 0 0 1 46 51 1 1 1 0 1 0 1 0 46 64 1 1 1 0 1 0 1 1 46 79 1 1 1 0 1 1 0 0 46 94 1 1 1 0 1 1 0 1 47 08 1 1 1 0 1 1 1 0 47 22 1 1 1 0 1 1 1 1 47 36 1 1 1 1 0 0 0 0 47 73 1 1 1 1 0 0 0 1 47 87 1 1 1 1 0 0 1 0 48 01 1 1 1 1 0 0 1 1 48 15 1 1 1 1 0 1 0 0 48 31 1 1 1 1...

Page 144: ...ion Interface PC Board Pilot Board 8 7 6 5 4 3 2 1 3 2 1 E1 E3 Art A 04583 Automation Interface PCB Connector J1 Rear Panel CPC Connector E6 E5 Main PC Board Automation Interface PCB Connector J4 NEG CSR Output Diodes Output Power Board Hooks for Raw Arc Voltage Output Diodes To Ground Stud TS2 TS1 ...

Page 145: ... J2 10 Open J2 11 DividedOutput Negative J2 12 Open J2 13 RemoteCurrentControl J2 14 RemoteCurrentControl J2 15 RemoteCurrentControl J2 16 Open J2 17 DCCommon J2 18 ArcVolts J2 19 Open J2 20 ArcVolts Connector J4 to CPC Connector on Power Supply Rear Panel J4 1 ArcVolts Through100Kohmresistor J4 2 Open J4 3 ArcVolts Through100Kohmresistor J4 4 LogicCommon J4 5 Open J4 6 Open J4 7 Open J4 8 Open J4...

Page 146: ... D i v i d e d O u t p u t P o s i t i v e t o C P C H o u s i n g P i n 6 D i v i d e d O u t p u t N e g a t i v e t o C P C H o u s i n g P i n 5 L o g i c C o m m o n t o C P C H o u s i n g P i n 8 O p e n O p e n O p e n O p e n O p e n O p e n O p e n O p e n A r c V o l t s P o s i t i v e t o C P C H o u s i n g P i n 9 A r c V o l t s N e g a t i v e t o C P C H o u s i n g P i n 7 O p e...

Page 147: ... p e n O p e n O p e n O p e n O p e n O p e n O p e n O p e n A r c V o l t s P o s i t i v e P r o p r i e t a r y A r c V o l t s N e g a t i v e P r o p r i e t a r y R e m o t e C u r r e n t C o n t r o l O p t i o n a l R e m o t e C u r r e n t C o n t r o l O p t i o n a l R e m o t e C u r r e n t C o n t r o l O p t i o n a l To Main PC Board Terminal J27 3 To Main PC Board Terminal J27...

Page 148: ...Run SetSwitch J18 8 Run SetSwitch J23 1 Notused J23 2 Notused J23 3 Notused J24 1 GasSolenoid SOL1 J24 2 GasSolenoid SOL1 J24 3 PressureSwitch PS1 J24 4 PressureSwitch PS1 J24 5 MainContactor W1 J24 6 MainContactor W1 J24 7 Notused J24 8 Notused E2 E3 E1 Secondary Transformer 32 27 Input Diode mounts to center chassis E1 E3 E2 Fuse LT1 E33 J25 E10 E20 E7 E15 E30 E27 E32 J26 E23 J23 J24 J34 J33 J32...

Page 149: ...J34 2 PIP J34 3 Notused J34 4 Notused J34 5 TorchSwitchReturn J34 6 TorchSwitch J43 1 12vdctoLogicPCB J43 2 12vdctoLogicPCB J43 3 DCCom J43 4 DCCom J43 5 MC1On J43 6 TipSense J43 7 Run Set J43 8 PressureGood J43 9 Overtemp J43 10 CSR J43 11 Gason J43 12 DCOK J43 13 OVTEMP J43 14 ACOK J43 15 TorchSwitch J43 16 TorchSwitchReturn J43 17 12vdc J43 18 POTHigh J43 19 POTWiper J43 20 POTLow J43 21 GateDr...

Page 150: ...n Off and Run Rapid Restart Set Switches To Fans To Main Input Contactor Test Connector To Heat Sink Temp Sensor Heat Sink Temp Sensor To Inductor Temp Sensor To Press Switch Solenoid Contactor Fuse Secondary Transformer Copper Strap 1 To Input Contactor To Auto Interface Board J1 5 To Auto Interface Board J1 6 To Main Transformer 33 78 1 LT1 32 27 2 3 To POT LED PCB or to Optional Remote Current ...

Page 151: ...Connector To On Off and Run Rapid Restart Set Switches To Fans To Main Input Contactor Test Connector To Heat Sink Temp Sensor Heat Sink Temp Sensor To Inductor Temp Sensor To Press Switch Solenoid Contactor Fuse Secondary Transformer 1 To Input Contactor To Auto Interface Board J1 5 To Auto Interface Board J1 6 To Main Transformer LT1 32 27 2 3 To POT LED PCB or to Optional Remote Current Control...

Page 152: ...cLow 12vdc P1 18 LogicLow PotHigh P1 19 LogicLow PotHigh P1 20 Pot Low P1 21 GateDriveBReturn P1 22 GateDriveB P1 23 GateDriveAReturn P1 24 GateDriveA P1 25 Out Sense P1 26 CurrentSense P1 27 CurrentSense P1 28 CurrentSenseReturn P1 29 CurrentSenseReturn P1 30 DCCom P1 31 DCCom P1 32 Not Used P1 33 I Sense P1 34 Not Used P1 35 Not Used P1 36 TipVolts INDICATORS D13 INVON D25 DRAGON D33 SWITCHON TE...

Page 153: ...3 fromMainPCBoard J27 3 PotLow J14 4 12vdc J27 4 J14 5 LogicLowSignalforACOKIndicatorfromLogicPCBoard J27 5 J14 6 LogicLowSignalforGASIndicatorfromLogicPCBoard J27 6 J14 7 LogicLowSignalforTEMPIndicatorfromLogicPCBoard J27 7 J14 8 LogicLowSignalforDCIndicatorfromLogicPCBoard J27 8 D4 FrontPanelACIndicator D5 FrontPanelTEMPIndicator D6 FrontPanelGASIndicator D7 FrontPanel DCIndicator ...

Page 154: ...APPENDIX A 24 Manual 0 4691 A APPENDIX 23 OUTPUT DIODE LAYOUT s s E48 E50 E54 E53 E34 E39 E60 E56 E34 E39 E60 E56 E48 E50 E54 E53 Art A 04570 ...

Page 155: ...B Output Diodes E32 To Output Inductor E45 E49 E61 Work Cable E57 E58 E43 To Output Inductor E52 E35 E62 To Torch To Pilot PCB To Main PCB To Pilot PCB J39 J40 E37 Chassis Ground To Trans former To Trans former TP1 To Torch E64 To Pilot Board E47 Raw Arc Voltage Connections E1 E2 Art A 04605 ...

Page 156: ...BoardJ1 3 J1 2 DCCommon toAutomationInterfacePCBoardJ1 2 J28 1 12vdc J28 2 DCCom J28 3 NotUsed J28 4 NotUsed J28 5 LogicLowCSR J28 6 NotUsed J28 7 NotUsed J28 8 PilotRe attach E58 ToPowerOutputPCBoardTerminalE58 E62 ToPowerOutputPCBoardTerminalE62 Art A 04582 Connector J28 Connector J1 Connector E62 Connector E58 ...

Page 157: ...ENDIX 26 28VAC CIRCUIT DIAGRAM 1 2 5 6 3 4 5 6 Main Power PC Board Auxiliary Transformer Voltage Protection CRT 12 Regulator J18 J24 12vdc W1 SOL ON OFF Switch A 03710 primary secondary Fuse 2 3 J23 Test K5 K4 J8 1 4 Line Voltage J11 1 ...

Page 158: ... 29 30 31 32 33 34 35 36 TS2 P32 J32 1 2 1 2 P29 NTC 1 2 3 4 1 4 2 3 J29 TS1 TEMP AC P14 P27 J27 J14 8 6 7 4 1 5 2 3 36 38 37 8 6 5 2 3 1 4 7 8 3 5 2 7 1 4 6 35 GAS 41 40 39 42 8 6 7 1 4 5 2 3 12V POT LOW OVERTEMP POT WIPER POT HIGH DC GAS AC DC 25 24 28VAC B SET 21 RUN 22 28VAC A 23 SW1 SW2 26 8 3 5 2 7 1 4 6 8 6 7 1 4 5 2 3 P18 J18 230V 6 6 7 230V 7 3 5 2 1 4 6 6 1 4 5 2 3 FAN1 FAN2 M1 M2 P15 J1...

Page 159: ... IS FOR REFERENCE ONLY SENSE POWER OUTPUT BOARD ASSY 19X2191 E56A E60A E37 E58 DC COM ISENSE 12VDC J40 5 3 7 6 4 8 2 1 CSR 1 5 7 3 P40 2 18 8 4 17 15 14 6 E58 J28 2 PILOT BOARD E62 8 1 E58 ASSY 19X2157 5 E49 E45 E35 E61 E32 E64 E43 E62 E36 E57 E63 E62 E35 WORK T O R C H E64 E64 L1 W1 F1 F2 M1 M2 TS1 TS2 FUSE 6 10A 600V KTK MAIN CONTACTOR OUTPUT INDUCTOR TEMP SENSOR INDUCTOR TEMP SENSOR IGBT HEATSI...

Page 160: ...8 6 7 4 1 5 2 3 36 38 37 8 6 5 2 3 1 4 7 8 3 5 2 7 1 4 6 35 GAS 41 40 39 42 8 6 7 1 4 5 2 3 12V POT LOW OVERTEMP POT WIPER POT HIGH DC GAS AC DC 25 24 28VAC B SET 21 RUN 22 28VAC A 23 SW1 SW2 26 8 3 5 2 7 1 4 6 8 6 7 1 4 5 2 3 P18 J18 230V 6 6 7 230V 7 3 5 2 1 4 6 6 1 4 5 2 3 FAN1 FAN2 M1 M2 P15 J15 2 1 3 4 2 1 3 4 W1 W1 W1 P24 W1 PS1 SOL1 B A 8 3 5 2 7 1 4 6 J24 8 6 7 1 4 5 2 3 12 13 11 10 8 9 J2...

Page 161: ...E ONLY SENSE POWER OUTPUT BOARD ASSY 19X2191 E56A E60A E37 E58 DC COM ISENSE 12VDC J40 5 3 7 6 4 8 2 1 CSR 1 5 7 3 P40 2 18 8 4 17 15 14 6 E58 J28 2 PILOT BOARD E62 8 1 E58 ASSY 19X2157 5 E49 E45 E35 E61 E32 E64 E43 E62 E36 E57 E63 E62 E35 WORK T O R C H E64 E64 L1 W1 F1 F2 M1 M2 TS1 TS2 FUSE 6 10A 600V KTK MAIN CONTACTOR OUTPUT INDUCTOR TEMP SENSOR INDUCTOR TEMP SENSOR IGBT HEATSINK MAIN TRANSFOR...

Page 162: ... 19 20 17 18 11 8 1 2 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 7 D33 ASSY 19X2189 DC COM W1 ON D25 GAS ON DC COM DC COM P13 J12 J43 P1 INV ON DRAG ON SW ON ASSY 19X1775 LOGIC 8 3 5 2 7 1 4 6 8 6 7 4 1 5 2 3 DC COM TIP VOLTS 12VDC I SENSE OUT SENSE CSR TIP SENSE 71 70 77 75 74 73 72 8 3 5 2 7 1 4 6 8 6 7 1 4 5 2 3 PIP 3 5 2 1 4 6 6 1 4 5 2 3 8 TORCH SW TORCH SW RTN PIP PIP RTN 2 TORCH SW 78 ...

Page 163: ...01593 REL AA W1 L1 F1 F2 SW1 SW2 M1 M2 PS1 SOL1 T5 TS1 TS2 MAIN CONTACTOR TEMP SENSOR IGBT HEATSINK TEMP SENSOR INDUCTOR OUTPUT INDUCTOR MAIN TRANSFORMER FAN 4 5 220VAC PRESSURE SWITCH GAS SOLENOID SWITCH ON OFF SWITCH RUN SET RAR FAN 4 5 220VAC F4 D7 B2 B1 C1 F4 F4 C1 C1 D4 E1 F3 D1 1 5 J28 7 2 3 P40 2 18 PILOT BOARD 8 4 E62 17 8 1 E58 15 ASSY 19X2157 14 6 5 DC COM ISENSE 12VDC J40 5 3 7 6 4 8 2 ...

Page 164: ...D25 GAS ON DC COM DC COM P13 J12 J43 P1 INV ON DRAG ON SW ON LOGIC 8 3 5 2 7 1 4 6 8 6 7 4 1 5 2 3 DC COM TIP VOLTS 12VDC I SENSE OUT SENSE CSR TIP SENSE 71 70 77 75 74 73 72 8 3 5 2 7 1 4 6 8 6 7 1 4 5 2 3 PIP 3 5 2 1 4 6 6 1 4 5 2 3 8 TORCH SW TORCH SW RTN PIP PIP RTN 2 TORCH SW 78 79 80 81 J34 P34 1 4 3 J23 3 2 1 8 3 5 2 7 1 4 6 J24 8 6 7 1 4 5 2 3 12 13 11 10 8 9 J25 J30 J31 J26 1 2 1 2 1 2 1 ...

Page 165: ...93 REL AA W1 L1 F1 F2 SW1 SW2 M1 M2 PS1 SOL1 T5 TS1 TS2 MAIN CONTACTOR TEMP SENSOR IGBT HEATSINK TEMP SENSOR INDUCTOR OUTPUT INDUCTOR MAIN TRANSFORMER FAN 4 5 220VAC PRESSURE SWITCH GAS SOLENOID SWITCH ON OFF SWITCH RUN SET RAR FAN 4 5 220VAC F4 D7 B2 B1 C1 F4 F4 C1 C1 D4 E1 F3 D1 1 5 J28 7 2 3 P40 2 18 PILOT BOARD 8 4 E62 17 8 1 E58 15 14 6 5 DC COM ISENSE 12VDC J40 5 3 7 6 4 8 2 1 CSR E35 WORK T...

Page 166: ...WIPER RUN SET TIP SENSE CSR 24 25 26 27 28 29 30 31 ISENSE 32 33 CURRENT SENSE RTN 34 35 36 CURRENT SENSE OVERTEMP OVTEMP 12VDC DC OK 4 5 3 6 7 12 9 15 10 14 16 13 19 20 17 18 11 8 1 2 POT HIGH 12VDC AC OK DC COM TORCH SW RTN 4 5 3 6 7 12 9 15 10 14 16 13 19 20 17 18 11 8 1 2 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 4 5 3 6 12 9 15 10 14 16 13...

Page 167: ...OR CURRENT L1 L1 OUTPUT INDUCTOR D7 MAIN TRANSFORMER 12VDC J40 P40 WORK T O R C H OUTPUT INDUCTOR NOTES UNLESS OTHERWISE SPECIFIED 1 DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS IS FOR REFERENCE ONLY HAS SENSE Vo POWER OUTPUT BOARD ASSY 19X2191 CM151 600V 3PH SYSTEM 42X1189 D AA THERMAL DYNAMICS INDUSTRIAL PARK No 2 WEST LEBANON NH 03784 603 298 5711 E49 E45 E62 E35 E43 E61 E3 E1 E58 E37 E36 E57 E63 ...

Page 168: ...SENSE OVERTEMP OVTEMP 12VDC DC OK 4 5 3 6 7 12 9 15 10 14 16 13 19 20 17 18 11 8 1 2 POT HIGH 12VDC AC OK DC COM TORCH SW RTN 4 5 3 6 7 12 9 15 10 14 16 13 19 20 17 18 11 8 1 2 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 4 5 3 6 12 9 15 10 14 16 13 19 20 17 18 11 8 1 2 4 5 3 6 7 12 9 15 10 14 16 13 19 20 17 18 11 8 1 2 21 22 23 24 25 26 27 28 29 ...

Page 169: ...D7 MAIN TRANSFORMER 12VDC J40 P40 WORK T O R C H OUTPUT INDUCTOR NOTES UNLESS OTHERWISE SPECIFIED 1 DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS IS FOR REFERENCE ONLY HAS SENSE Vo POWER OUTPUT BOARD ASSY 19X2191 CM151 600V 3PH SYSTEM 42X1189 D AA THERMAL DYNAMICS INDUSTRIAL PARK No 2 WEST LEBANON NH 03784 603 298 5711 5 4 E 9 4 E E62 E35 E43 E61 E3 E1 E58 E37 E36 E57 E63 J28 PILOT BOARD 8 5 PLUGS INT...

Page 170: ...og numbers for torches leads w solenoid for replacement leads for torches w solenoid Added publication history to manual Mar 29 2006 AA Dropped mention of leads extensions Used new cover style April 17 2006 AB Updated torque specs on IGBTs and output diodes to 35 in lb 3 95 Nm July 6 2006 AC Updated control panel art October 5 2006 AC 01 Added patent information and newer revision control to inclu...

Page 171: ...strict 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 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 V...

Page 172: ...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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