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APPENDIX

A-12

Manual 0-2957

APPENDIX 10: OUTPUT BOARD WIRING DIAGRAM

Art # A-03655

E36

Output

Diode A

Output

Diode B

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

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Summary of Contents for CUTMASTER 81

Page 1: ...PLASMA CUTTING SYSTEM 81 CUTMASTER Rev AC 01 Date April 13 2007 Manual 0 2957 Operating Features A 04517 Service Manual...

Page 2: ......

Page 3: ...04 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 as...

Page 4: ......

Page 5: ...er Assembly Specifications 3 3 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 4 05 Troubl...

Page 6: ...0 Volt Units A 6 APPENDIX 5B MAIN PC BOARD WIRING LAYOUT 400 Volt 415 Volt 460 Volt and 600 Volt Units A 7 APPENDIX 6 LED POT PC BOARD LAYOUT A 8 APPENDIX 7 INPUT DIODE PC BOARD LAYOUT A 9 APPENDIX 8...

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: ...this manual PLASMA ARC 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: ...onsumable 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 improperl...

Page 15: ...ust be properly packaged in protective material and returned intact per normal procedures 2 03 Service Responsibilities The service technician should be familiar with the equip ment and its capabiliti...

Page 16: ...INTRODUCTION 2 2 Manual 0 2957 This Page Left Blank...

Page 17: ...ts Input Power 40 C 104 F 20 60 Amps Continuously Adjustable Particulates to 20 Microns CutMaster 81 Power Supply Duty Cycle 50 460 VAC 414 506 VAC Three Phase 60 Hz 600 VAC 517 632 VAC Three Phase 60...

Page 18: ...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 Pressure Regulator...

Page 19: ...d indicates the power supply is overheated GAS When lighted indicates that adequate input air pressure for power supply operation is present DC When lighted indicates that power supply output circuits...

Page 20: ...DESCRIPTION 3 4 Manual 0 2957 This Page Left Blank...

Page 21: ...tor turns on The GAS indicator is ON when there is sufficient gas pressure in the power supply to enable power sup ply operation NOTE Minimum gas pressure for power supply operation is lower than the...

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: ...oubleshooting identify symptoms and test the unit for proper operation Follow the instructions as given to iden tify the possible symptom s and the defective circuit After repairs are complete run the...

Page 25: ...n as noted then note the symp tom and proceed to Subsection 4 09 Main Arc Problems 4 07 Main Input and Internal Power Problems A Opening Power Supply Enclosure The cover of the Power Supply must be re...

Page 26: ...er cable connections inside Power Supply a Refer to System Schematic and correct if needed 7 Defective input power cable a Replaceinputpowercable 8 Fuse blown inside Power Supply a Replace internal Fu...

Page 27: ...Switch a Shut input power off 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...

Page 28: ...itch 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 p...

Page 29: ...ms 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 is turned on...

Page 30: ...Main Printed Circuit Board Layout Logic PCB Not Shown Art A 03651 INPUT DIODE E22 E1 E2 E3 TP1 E7 E15 TP4 U1 J24 J32 J29 E10 E20 E4 J30 E33 J18 J26 E27 J23 E30 J33 J31 E23 E32 J27 J25 IGBT A IGBT B J...

Page 31: ...rrect 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 s a Measure between the following points on the IGBTs IGB...

Page 32: ...s low a 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 conn...

Page 33: ...the air Any oil or moisture in the air will be visible on the lens Do not start an arc c Purge system If problem corrected add filters in line with air source 3 Incorrect torch parts a Inspect the to...

Page 34: ...actor a Check per Subsection 4 10 D B When operating the amperage drops off after the main cutting arc starts 1 Torch tip contacts workpiece Lift the torch tip off the work At output settings over 40...

Page 35: ...er at the source before dis assembling the power supply torch or torch leads Testing of diode modules requires a digital volt ohm meter that has a diode test scale Remember that even if the diode modu...

Page 36: ...e Drop E1 E15 Open E15 E7 Diode Drop E7 E15 Open 208 230V Input Diode PCB Indication can be twice other indications c The meter should indicate a diode drop in one di rection and an open in the other...

Page 37: ...est 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...

Page 38: ...J23 1 to J23 3 on the Main PC Board a If greater than 30 VAC input line power is too high b If there is no AC power check the fuse If the fuse is okay the auxiliary transformer is faulty Replace the...

Page 39: ...should flow then stop after 2 seconds Front panel DC indicator should turn on 6 Measure open circuit voltage between E61 to E43 at the Output Power PC Board Voltage should be greater than 200 V If vo...

Page 40: ...TROUBLESHOOTING 4 20 Manual 0 2957 This Page Left Blank...

Page 41: ...the first 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...

Page 42: ...er up and away from the unit for access to the ground wire connection on the inside of the cover 3 Remove the nut and washer from the ground stud on the inside of the cover 4 Installthereplacementcove...

Page 43: ...ESTART SET Switch Replacement 1 Remove the cover per subsection 5 04 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 Wir...

Page 44: ...ntactor from the input cable 4 Disconnect all other wires connected to the Input Contactor 5 Remove the two nuts and washers securing the Input Contactor to the base of the power supply 6 Position the...

Page 45: ...e 3 Locate the IGBT Circuit PC Boards or Input Di ode mounted within the Main Power PC Board Refer to Appendix pages for location and posi tion 4 For IGBTs remove the small jumpers between the IGBT an...

Page 46: ...e antistatic procedures in subsection 5 02 1 Remove cover per subsection 5 04 A 2 Remove the Logic PC Board per subsection 5 06 C 3 Disconnect all wire and cable connections to the Main PC Board Refer...

Page 47: ...ting until fully seated and it will automatically lock B Filter Regulator Bracket Replacement 1 Remove the four bolts securing the Regulator Bracket to the Rear Panel 2 Remove the nut securing the Fil...

Page 48: ...rom the Adapter Fitting on the output side of the Solenoid Assembly 6 Install the replacement Pressure Switch Solenoid Assembly by reversing steps 2 5 Once installed the Solenoid Assembly should fit s...

Page 49: ...10 Pass the Work Cable through the hole in the bot tom of the Fan Panel Ensure that the grommet is in place in the hole 11 Connect the Work Cable to terminal E61 on the Power Output PC Board Secure t...

Page 50: ...ransformer or the Output In ductor Follow these steps for access to either compo nent 1 Remove the Power Supply cover per subsection 5 04 A 2 Release the tab on the vertical face of the Heat sink Shro...

Page 51: ...left forward and right rear corners of the Inductor base 4 Remove the Inductor as follows a Note the position of the wires leading from the Inductor b Lift out the Inductor through the opening at the...

Page 52: ...the wire harnesses passing through the right rearward edge of the Heatsink Shroud 7 Reinstall the Pilot Board Reconnect the wires to the Pilot Board Reconnect the torch receptacle ground wire to the c...

Page 53: ...6 07 Right Side Internal Component 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...

Page 54: ...nal Replacement Parts Item Qty Description Catalog 1 1 Cover with labels 9 7997 2 Rear Panel provide data tag information when ordering 1 For 208 230 Volt Power Supplies 9 8323 1 For 400 Volt 415 Volt...

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

Page 56: ...1 PCB Assembly Logic Board for Non Mechanized units 9 7992 4 1 PCB Assembly Logic Board for Mechanized units 9 9440 5 1 PCB Assembly Kit IGBT Circuit for 208 230 Volt 400 Volt 415 Volt and 460 Volt P...

Page 57: ...Manual 0 2957 6 5 PARTS LISTS NOTE Illustration may vary slightly from unit 3 5 4 1 7 5 Art A 03717 6 2 2A OR 8...

Page 58: ...414 3 1 Regulator Mounting Bracket 9 7589 4 Input Power Cable 1 for 208 230 Volt Units 9 8596 1 for 400 Volt Three Phase units 9 8562 1 for 400 Volt and 415 Volt CE units 9 8553 1 for 460 Volt Three P...

Page 59: ...Assembly Main Transformer T5 for 208 230 Volt units 9 8589 for 400 Volt and 415 Volt units 9 8603 for 460 Volt units 9 8584 for 600 Volt units 9 8635 5 1 Assembly Output Inductor L1 9 8591 6 1 Assemb...

Page 60: ...ng Screws 7 7500 1 Bracket Filter Mounting 9 7535 1 Dual Stage Air Filter Assembly 9 7527 1 Replacement First Stage Cartridge 9 1021 1 Replacement Second Stage Cartridge 9 1022 Not Shown 1 Extended Wo...

Page 61: ...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 62: ...PARTS LISTS 6 10 Manual 0 2957 This Page Left Blank...

Page 63: ...use replaceable element fuses like UL Class H or one time fuses like UL Class K5 Input Power Input Current Input Suggested Sizes See Notes Voltage Freq 1 Ph 3 Ph 1 Ph 3 Ph Fuse Amps Wire AWG Wire Can...

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: ...c P1 18 Logic Low Pot High P1 19 Logic Low Pot High P1 20 Pot Low P1 21 Gate Drive B Return P1 22 Gate Drive B P1 23 Gate Drive A Return P1 24 Gate Drive A P1 25 Out Sense P1 26 Current Sense P1 27 Cu...

Page 66: ...5 1 Fan M1 J15 2 Fan M1 J15 3 Not used J15 4 Not used J15 5 Fan M2 J15 6 Fan M2 J16 1 Not used J16 2 Not used J17 1 Not used J17 2 Not used J18 1 Not used J18 2 Not used J18 3 28 VAC B J18 4 28 VAC A...

Page 67: ...Not used J34 4 Not used J34 5 Torch Switch Return J34 6 Torch Switch J43 1 12 vdc to Logic PCB J43 2 12 vdc to Logic PCB J43 3 DC Com J43 4 DC Com J43 5 MC1 On J43 6 Tip Sense J43 7 Run Set J43 8 Pres...

Page 68: ...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 Contact...

Page 69: ...Inductor Temp Sensor To Press Switch Solenoid Contactor Fuse Secondary Transformer To Main Transformer To Logic Board via Connector To Power Output Board To On Off and Run Rapid Restart Set Switches T...

Page 70: ...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 Logic Low Signal for TEMP Indicator from Logic PC Bo...

Page 71: ...Manual 0 2957 A 9 APPENDIX APPENDIX 7 INPUT DIODE PC BOARD LAYOUT Art A 03703 E18 E13 E5 E14 E16 E8 E6 19x1811...

Page 72: ...APPENDIX A 10 Manual 0 2957 APPENDIX 8 IGBT CIRCUIT PC BOARD LAYOUT B B A 03704 TP1 J3A E11A E9A E12A E21A E19A E17A J7A TP2 TP1 J3B E11B E9B E12B E21B E19B E17B J7B TP2...

Page 73: ...Manual 0 2957 A 11 APPENDIX APPENDIX 9 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...

Page 74: ...A 03655 E36 Output Diode A Output Diode B 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 Gr...

Page 75: ...Low CSR J28 6 Not Used J28 7 Not Used J28 8 Not Used E58 To Power Output PC Board Terminal E58 E62 To Power Output PC Board Terminal E62 NOTES 1 Pilot PC Board with receptacle J1 may replace PC Board...

Page 76: ...DIX 12 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 Tes...

Page 77: ...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...

Page 78: ...P 4 Green Switch 2 Orange PIP 3 White Switch 1 Black PIP Negative Plasma 8 Ground ATC Male Connector Front View A 03701 ATC Female Receptacle Front View ATC Male Connector Front View Negative Plasma 3...

Page 79: ...r Supply Circuitry Art A 03797 1 2 5 6 4 3 8 7 1 2 5 6 4 3 8 7 Torch Switch Green White To Power Supply Circuitry Torch Unshielded Mechanized SL100 Machine Torch Leads Leads with ATC Connector and Rem...

Page 80: ...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...

Page 81: ...O M M O C C D N O M M O C C D OUTPUT INDUCTOR NOTES UNLESS OTHERWISE SPECIFIED IS FOR REFERENCE ONLY REL DLL 05 07 03 SENSE POWER OUTPUT BOARD ASSY 19X1914 E50A E48A E53A E54A E56A E60A E39A E34A E37...

Page 82: ...9X1775 LOGIC ASSY 19X2284 CM81 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...

Page 83: ...OF CIRCUITRY INSIDE PCB BLOCKS IS FOR REFERENCE ONLY SENSE POWER OUTPUT BOARD ASSY 19X1914 01 09 06 RS ECO B028 W1 L1 F1 F2 SW1 SW2 M1 M2 PS1 SOL1 T5 TS1 TS2 MAIN CONTACTOR TEMP SENSOR IGBT HEATSINK...

Page 84: ...RTEMP 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...

Page 85: ...DUCTOR D7 MAIN TRANSFORMER DC COMMON DC COMMON 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 REL DLL S...

Page 86: ...c n for logic board for mechanized units and per ECO 101948 torque spec for replacement input diode Started using new cover styles Added publication history 9 29 06 AA 01 Added patent information and...

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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