Thermal Dynamics Cutmaster 82, Service Manual

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cutmaster 82
Manual 0-4980 5-9 SERVICE
B. Cover Installation
1. Reverse previous procedures for cover installa-
tion.
NOTE
When installing the upper screws, attempt to
reuse the original threads. The easaiest way to
do this is by turning the screw counter-clockwise
until you feel the threads lign up, then begin to
turn the screw clockwise to tighten to 15-18 in.
lbs.. Do not over tighten.
C. Pre Power Up Tests
Prior to applying primary line power to the unit,
perform the following checks to prevent component
failure or blowing primary fuses. The troubleshoot-
ing guide will assume these tests were done and no
failure was found or that any failures found were
corrected.
1. Main Contactor (W1) Check – Section 5.11 A
2 Input Diode Module Test – Section 5.11 B
3 Input Capacitor Pcb Test –Section 5.11 C
4 IGBT Modules Test – Section 5.11 D
5 Output Diode Module Test – Section 5.11 E
6 Pilot IGBT Test – Section 5.11 F
If all of the Pre Power-Up Tests are ok, proceed with
the trouble shooting guide.
CAUTION
Due to the close proximity of the Main Pcb to the
Capacitor Pcb, It is recommended to use an insu-
lated meter probe when making measurements on
the J2 connector on the Main Pcb. Do not short
between the pins. Do not short to the Capacitor
Pcb connections.
D. Initial Set up Conditions
This section is to help isolate the defective circuit
before troubleshooting, identify symptoms, and test
the unit for proper operation. Follow the instructions
as given to identify the possible symptom(s) and the
defective circuit. After repairs are complete, run the
following tests again to verify that the unit is fully
operational.
1. Connect gas supply to rear of Power Supply.
2. Turn on gas supply and set operating pressure
per pressure setting label on power supply.
3. Set the Power Supply controls as follows:
• ON/OFF SWITCH to OFF position
• Turn FUNCTION CONTROL SWITCH to SET
position
• CURRENT CONTROL POTENTIOMETER to
MAXIMUM position, fully clockwise.
E. Main Input and Internal Power Test
1. Connect Primary Line power to the unit.
2. Turn the ON/OFF SWITCH ( SW1) to ON position
and observe the following:
• Software version is displayed (See section 5.04
Fault Indicators)
After approx. three (3) seconds
• Inrush relay on PCB1 energizes, starting pre-
charging of working capacitors.
• W1 energizes
• AC and GAS Indicators come on
• Gas flows
• Fans turn on
3. Adjust the pressure regulator to set the gas pres-
sure as specified in charts.
STANDOFF
CutMaster 82 Gas Pressure Settings
Leads
Length
SL60
(Hand Torch)
SL100
(Mechanized Torch)
Up to 25'
(7.6 m)
75 psi
5.2 bar
75 psi
5.2 bar
Each
additional
25'
(7.6 m)
Add 5 psi
0.4 bar
Add 5 psi
0.4 bar
DRAG
CutMaster 82 Gas Pressure
Settings
Leads
Length
SL60
(Hand Torch)
Up to 25'
(7.6 m)
80 psi
5.5 bar
Each
additional 25'
(7.6 m)
Add 5 psi 0.4
bar