Thermal Dynamics CUTMASTER SL100SV Operating Manual Download Page 1

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AUTOMATED
PLASMA CUTTING SYSTEM

CUTMASTER

™

Rev. AC.01 Date:

April 2, 2007

Manual #

0-4640

Operating Features:

Art # A-04611

Operating Manual

SL100SV

PLASMA CUTTING
MACHINE TORCH

Summary of Contents for CUTMASTER SL100SV

Page 1: ...AUTOMATED PLASMA CUTTING SYSTEM 51 CUTMASTER Rev AC 01 Date April 2 2007 Manual 0 4640 Operating Features Art A 04611 Operating Manual SL100SV PLASMA CUTTING MACHINE TORCH...

Page 2: ...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 Th...

Page 3: ...006 2007 by Thermadyne 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...

Page 4: ...nection to SC 11 Standoff Control 3 12 3 09 Power Supply Connection to Alternate Standoff Control 3 13 3 10 Automation Interface PC Board Set up 3 16 3 11 Optional Remote Current Control Harness Insta...

Page 5: ...ssories 6 2 6 05 Power Supply Major External Replacement Parts 6 3 6 06 Front Panel Replacement Parts 6 4 6 07 Left Side Internal Replacement Parts 6 6 6 08 Rear Panel Replacement Parts 6 8 6 09 Right...

Page 6: ...CONNECTIONSTO ALTERNATE CNC HARNESS A 17 APPENDIX 18 MAIN PC BOARD LAYOUT A 18 APPENDIX 19 MAIN PC BOARD WIRING LAYOUT 208 230 Volt POWER SUPPLIES A 20 APPENDIX 20 MAIN PC BOARD WIRING LAYOUT 400 Volt...

Page 7: ...TABLE OF CONTENTS continued Power Supply SL100SV Torch with Solenoid A 36 APPENDIX 31 Publication History A 38 Global Customer Service Contact Information Inside Rear Cover...

Page 8: ......

Page 9: ...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 10: ...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 11: ...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 12: ...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 13: ...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 14: ...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 15: ...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 16: ...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 17: ...power AC is low or the output voltage DC is higher than shown in this chart Input Power Automated CutMaster 51 Power Supply Specifications All Units 40 60 100 40 C 104 F 208 230 VAC 187 253 VAC Single...

Page 18: ...ut Voltage Frequency 3 Ph 3 Ph Fuse Amps Wire mm2 Volts Hz kVA Amps 3 Ph 3 Ph CE CutMaster 51 400 50 7 9 11 5 15 4 Input Suggested Sizes See Notes Line Voltages with Suggested Circuit Protection and W...

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 Therm...

Page 20: ...assembledatthefactoryandneedsonlytobeinstalledonthepowersupply C High Pressure Regulators Highpressureregulatorsareavailable Theregulatorsareusedtosetthepropercompressedairpressure NOTE Regulators sho...

Page 21: ...ssure 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...

Page 22: ...witch 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 parti...

Page 23: ...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...

Page 24: ...e 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...

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 befo...

Page 26: ...rotection and wiring requirements refer to table in Section 2 03 B Connections to 400 Volt 460 Volt or 600 Volt Three Phase Power ThesePowerSuppliesareequippedwithafour conductorinputpowercableforthre...

Page 27: ...Section2forpowercablespecifications 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...

Page 28: ...ctionisthesameforcompressedairfromacompressorfrom highpressurecylinders Refertosubsection3 4 Bor3 4 Cifanadditionalairlinefilteristobeinstalled 1 Connect the air line to the inlet port The illustratio...

Page 29: ...Use only Synflex or equivalent grade hose The illustration shows typical fittings as an example NOTE For a secure seal apply thread sealant to the fitting threads according to the maker s instruction...

Page 30: ...rding to manufacturer s instructions Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air passages in the torch b Connect the two stage filter...

Page 31: ...w out any dust which may be present 3 Thecylindermustbeequippedwithanadjustablehigh pressureregulatorcapableofoutletpressuresupto100psi 6 9bar maximumandflowsofatleast500scfh 236 lpm 4 Connect supplyh...

Page 32: ...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 Secur...

Page 33: ...quality of air 1 PuttheON OFFswitchintheON up position 2 PuttheRUN RAPIDAUTORESTART SETswitchintheSET down position 3 Placeaweldingfilterlensinfrontofthetorchandturnontheair Anyoilormoistureintheairwi...

Page 34: ...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 S...

Page 35: ...torchforproperconsumableparts Thepartssuppliedinthetorchmaynotbecorrectfortheoperator schosen amperagelevel Thetorchpartsmustcorrespondwiththetypeofoperation Art A 04173 Electrode Start Cartridge Tip...

Page 36: ...ationInterfacePCBoardconnectedtoaCPCconnectoronthepowersupplyrearpanel ForconnectiontotheThermalDynamicsSC 11StandoffControl alignandconnectthecablefromtheStandoffControltothe CPCconnector Checkforase...

Page 37: ...ripforconnectiontoalternateCNCcontrols ToconnectanalternateCNCControltothePowerSupply 1 RemovethePowerSupplyCover 2 Carefullyopenthelowerknockout belowthefactory installedCNCconnector onthePowerSupply...

Page 38: ...v 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...

Page 39: ...Manual 0 4640 3 15 INSTALLATION 3 Art A 04392 Main PC Board Connection Points for Raw Arc Voltage E24 E27 TORCH E27 Main PC Board RawArcVoltageConnectionPoints...

Page 40: ...stment ForoperationwithanyotherCNCequipment refertotheCNCsystemdocumentstodeterminethedivisionfactortheCNC systemrequires Proceedasfollows 1 Settheinterfacecontrolboardswitchesasindicatedintheappropri...

Page 41: ...nectors Installtheharnessasfollows To Pot LED Board Receptacle J14 To Automation Interface Board Receptacle J3 To Main PC Board Receptacle J27 Connector Plugs Art A 03945 4 Ensurethatthewireharnesswil...

Page 42: ...INSTALLATION 3 18 Manual 0 4640 3 This Page Left Blank...

Page 43: ...glines AC Indicator Steadylightindicatespowersupplyisreadyfor operation Blinkinglightindicatesunitisinpro tectiveinterlockmode Shutunitoff shutoffor disconnectinputpower correctthefault andre startthe...

Page 44: ...upply 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 Co...

Page 45: ...plyON 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 t...

Page 46: ...tart SETswitchtotheSET down position Gaswillflow 20 25 30 35 40 A A 03690 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...

Page 47: ...y andthecuttingarcrestartsinstantlywhenthepilotarc contactstheworkpiece Usethe RapidAutoRestart positionwhencuttingexpandedmetalorgratings orintrimming operationswhenanuninterruptedrestartisdesired J...

Page 48: ...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 Bod...

Page 49: ...ive 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 Reins...

Page 50: ...h ofthefaceofthecut B Nitride Build Up Nitridedepositscanbeleftonthesurfaceofthecutwhennitrogenispresentintheplasmagasstream Thesebuildupsmay createdifficultiesifthematerialistobeweldedafterthecutting...

Page 51: ...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 p...

Page 52: ...avy 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 cu...

Page 53: ...d 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 tra...

Page 54: ...earc penetratesthebottomoftheplate Asmotionbegins torchstandoffshouldbereducedtotherecommended1 8 1 4inch 3 6mm distanceforoptimumspeedandcutquality Cleanspatterandscalefromtheshieldcupandthetipassoon...

Page 55: ...orificediameter littleornodross smoothcutsurface Good Slightbevel 0 10 slightlywiderkerf 2 1 2xtip orificediameter somedross easilyremoved medium smoothcutsurface slighttopedgerounding 4 08 Cutting S...

Page 56: ...olts in mm IPM mm min 0 036 20 0 91 8 8208 40 65 0 188 4 8 0 00 96 0 19 4 80 341 8661 4 0 051 1 30 8 8208 40 65 0 188 4 8 0 00 97 0 19 4 80 300 7620 0 060 16 1 52 8 8208 40 65 0 188 4 8 0 10 98 0 19 4...

Page 57: ...C Volts in mm IPM mm min 0 038 20 0 95 8 8208 40 65 0 188 4 8 0 00 103 0 19 4 80 357 9067 8 0 050 18 1 27 8 8208 40 65 0 188 4 8 0 00 104 0 19 4 80 287 7289 8 0 063 16 1 60 8 8208 40 65 0 188 4 8 0 10...

Page 58: ...440 11176 0 052 18 1 32 8 8208 40 65 0 188 4 8 0 00 96 0 19 4 80 440 11176 0 064 16 1 63 8 8208 40 65 0 188 4 8 0 10 98 0 19 4 80 440 11176 0 079 14 2 01 8 8208 40 65 0 188 4 8 0 30 102 0 19 4 80 297...

Page 59: ...4 8 0 00 102 0 19 4 80 170 4318 0 051 1 30 8 8208 9 8245 40 65 1 88 4 8 0 00 103 0 19 4 80 148 3759 2 0 060 16 1 52 8 8208 9 8245 40 65 1 88 4 8 0 10 104 0 19 4 80 133 3378 2 0 075 14 1 91 8 8208 9 82...

Page 60: ...18 1 27 8 8208 9 8245 40 65 0 188 4 8 0 00 109 0 19 4 8 150 3810 0 063 16 1 60 8 8208 9 8245 40 65 0 188 4 8 0 10 110 0 19 4 8 122 3098 8 0 078 14 1 98 8 8208 9 8245 40 65 0 188 4 8 0 30 111 0 19 4 8...

Page 61: ...051 1 30 8 8208 9 8245 40 65 0 188 4 8 0 00 102 0 19 4 8 220 5588 0 064 16 1 63 8 8208 9 8245 40 65 0 188 4 8 0 10 104 0 19 4 8 220 5588 0 079 14 2 01 8 8208 9 8245 40 65 0 188 4 8 0 30 108 0 19 4 8 1...

Page 62: ...t Cat Amps PSI In mm SEC Volts in mm IPM mm min Material Torch SL100 with Shielded Tip Power Supply CutMaster 51 Automated Table Dry Gas Compressed Air Recommended Travel Speed Stand off Height Pierce...

Page 63: ...at Amps PSI In mm SEC Volts in mm IPM mm min Material Torch SL100 with Shielded Tip Power Supply CutMaster 51 Automated Table Dry Gas Compressed Air Recommended Travel Speed Stand off Height Pierce He...

Page 64: ...at Amps PSI In mm SEC Volts in mm IPM mm min Material Torch SL100 with Shielded Tip Power Supply CutMaster 51 Automated Table Dry Gas Compressed Air Recommended Travel Speed Stand off Height Pierce He...

Page 65: ...filterelementwillbevisibleandstillattachedto themainbodyoftheRegulator Filter 3 GraspthefilterelementandunscrewitfromtheRegulator Filterbody Thefilterelementwillcomeoffwithaspooland someadditionalpiec...

Page 66: ...ng 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 El...

Page 67: ...g the Filter Assembly as injury could result 3 LoosenthetwoboltsonthetopoftheFilterAssemblyenoughtoallowtheFilterElementstomovefreely 4 NotethelocationandorientationoftheoldFilterElements 5 Slideoutth...

Page 68: ...ghwithcompressedair CAUTION Dry the torch thoroughly before reinstalling E O Ring Lubrication AnO ringontheTorchATCMaleConnectorrequireslubricationonaregularbasis dependingonhowfrequentlythetorch isdi...

Page 69: ...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 N...

Page 70: ...irst then remedies Repair as needed being sure to verify that unit operatesproperlyafteranyrepairs C Common Symptoms A AC indicator OFF 1 Switch at main power panel in OFF open position a Close main p...

Page 71: ...es ACindicator ON GAS indicator OFF 1 Gas not connected a Check gas connections 2 Gas pressure too low for power supply operation a Adjustpressureto65 70psi 4 5 4 8bar E Torchwillnotpilot gasflows ACi...

Page 72: ...hield cup as irreparable damage to internal components may result 3 Upper O ring on torch head is in wrong position a Remove shield cup from torch check position of upper O ring Correct if necessary U...

Page 73: ...switchtoON up K Nocuttingoutput Torchpilots Gasflows Fanoperates AC Gas and DC indicator ON TEMP indicator OFF 1 Work cable not connected to work piece or connection is poor a Makesurethatworkcablehas...

Page 74: ...lades 3 Air flow obstructed TEMP indicator ON a Check for obstructed air flow around the unit and correct condition 4 Gas pressure too low GAS indicator OFF when torch switch is activated a Check sour...

Page 75: ...mbliesofthisunit Evidence ofunauthorizedrepairswillvoidthefactorywarranty NOTE Follow all instructions as listed and complete each in the order presented B How to Use the Troubleshooting Guide Thefoll...

Page 76: ...e thesymptomandproceedtoSubsection5 05 MainInputandInternalPowerProblems D Pilot Arc Test 1 Activatethetorch toestablishapilotarcandnotethefollowing Gasflows Preflowdelay twoseconds thenDCindicatortur...

Page 77: ...disassembling the Power Supply torch parts or torch and leads assemblies 1 Removethe upperscrewssecuringthecovertothemainassembly 2 Loosen butdonotremove thelowerscrews NOTE There is a ground wire att...

Page 78: ...y Tightenoradjustasneeded 4 Shield cup not fully tightened on torch head a Checkshieldcupforproperinstallation Donotovertighten 5 Main power line fuses blown a Replacemainpowerlinefuses 6 Improper inp...

Page 79: ...e E6 E27 E37 E43 E42 E36 E17 J21 E34 J20 E14 J26 J8 LT1 J18 J19 TP2 TP10 TP18 TP14 MainPrintedCircuitBoardLayout D AC andTEMP indicatorsON fandoesnotrun 1 Air flow through unit is restricted a Provide...

Page 80: ...PIDAUTORESTART SETswitch a Checkcontinuity 5 Faulty Gas Solenoid circuit a TestGasSolenoidcircuitperSubsection5 08 E repairasnecessary 6 Faulty Logic Board a Replace logic board F Gasflows ACindicator...

Page 81: ...ETswitch a PutswitchinSETposition DisconnectwireharnessconnectorfromMainPCBoardreceptacleJ18 Checkcontinuity throughwireharnesssockets7and8 Ifnocontinuity replaceswitch Art A 03751 Fuse F1 E1 E2 E3 E1...

Page 82: ...l 0 4640 5 3 Faulty Logic PCB a Measure for approximately12vdcbetweenP1 7andTP 1ontheLogicPCB If0vdcispresent replaceLogicPCB Art A 03883 TP6 D8 TP1 TP8 TP9 TP10 TP3 TP4 TP2 TP5 TP7 P1 1 to P1 36 P1 7...

Page 83: ...es 1 Shield cup is loose a Tightenshieldcupbyhand Donotovertighten 2 Torch tip electrode or start cartridge missing a Turnoffpowersupply Removeshieldcup installmissingparts 3 Start cartridge is stuck...

Page 84: ...r power supply operation is lower than minimum required for torch operation a Adjust gas pressure per pressure setting label on power supply B Torchwillnotpilot gasflows AC andGas indicators ON TEMP a...

Page 85: ...tsinkTempSensor TS1 DisconnectwireconnectorP2fromterminalJ2onMainPCBoard Check connectorpins1and2for10kohm 25 atambienttemperature Ifresistanceisnot10Kohm 25 replaceTS1 b CheckInductorTempSwitch TS2 D...

Page 86: ...ply Remove shield cup tip and start cartridge Check lower end fitting on start cartridge for free movement Replace cartridge if lower end fitting does not move freely Art A 07168 Spring Loaded Cylinde...

Page 87: ...GBT a MeasurebetweenthefollowingpointsontheMainPCBoard E4toE10 E10toE20 Voltage should be approximately 20 vdc before the start signal is active If voltage measures greater than 100 vdc when the start...

Page 88: ...irsource 3 Incorrect torch parts a Inspectthetorchparts replaceasneeded 4 Faulty leads a Checktorchleadscontinuity 5 Faulty torch a Checktorch 6 Faulty connection of wire 58 or 62 to Pilot Board a Che...

Page 89: ...tputwithnocontrol 1 Poor input or output connections to power supply a Checkallinputandoutputconnections 2 Faulty components in torch and leads assembly a Inspecttorchassembliesandreplaceifnecessary D...

Page 90: ...SERVICE 5 26 Manual 0 4640 5 Art A 03883 TP6 D8 TP1 TP8 TP9 TP10 TP3 TP4 TP2 TP5 TP7 P1 1 to P1 36 P1 7 LogicBoardLayout...

Page 91: ...etime Voltagemeasuredoninput capacitorsmustbezerobeforeperformingserviceonthepowersupply 2 DoNottouchelectricalcomponentswithanypartofthehumanbodywhenpowerisapplied 3 Keepawayfromanymovingparts 4 Hots...

Page 92: ...forward bias plus to negative andreversebias negativetoplus direction 5 Connectthevolt ohmmeterpositiveleadtotheanode ofthediodeandthenegativeleadtothecathode ofthediodefor forwardbiastesting referto...

Page 93: ...Open E3 E11 Diode Drop E11 E3 Open E12 E1 Diode Drop E1 E12 Open E12 E2 Diode Drop E2 E12 Open E12 E3 Diode Drop E3 E12 Open For208 230 VoltPowerSupplies Meter Meter Indication E2 E11 Diode Drop E11 E...

Page 94: ...irectionandanopenintheotherdirectionforeachcheck Replacethe OutputDiodeModuleBoard s ifthereadingsdonotmatchthechart 3 IGBTModuleBoardCircuitTest a Useanohmmetersetonthediodefunctionandmakethefollowin...

Page 95: ...FrontPanelisOFF checkforproperACinputvoltagebetweeninputcablesontheMainContactor Inputvoltageshouldbeasshowninthefollowingchart Ifnot checkforpropervoltageatthemainpowersource Input Power Test Points...

Page 96: ...theACindicator ontheFrontPanelshouldbeON Whenthetorchisactivated thegasbeginsto flow Whenthepreflowtimeisover theINVONindicatorontheLogicPCBenergizes andtheDCindicator ontheFront PanelturnsON IftheIN...

Page 97: ...tTest a UseanohmmetersettothediodefunctionandmakethefollowingmeasurementsontheIGBTBoardtotheMainPower Board Meter Meter Meter Meter Indication E3 E13 E35 E13 Diode Drop E13 E3 E13 E35 Open E15 E3 E15...

Page 98: ...thetorchswitchon theRemotePendant AftertwosecondsINVONindicatorontheLogicPCBshouldcomeonandremainon IfINVONindicatordoesnotremainon replaceLogicPCB IfINVONindicatordoesremainon thencheckforapproximate...

Page 99: ...tionsareprovidedwiththereplacementpart A Cover Removal 1 Removetheupperscrewswhichsecurethecovertothemainassembly NOTE There is a ground wire connection to the inside of the unit There is no need to d...

Page 100: ...ndle thenliftthebaseoftheunitawayfromthe TubeHandle 4 Witharubbermallet separatethetwohandleendsasshownbelow 5 InstallthereplacementTubeHandlebyreversingtheabovesteps 6 Reinstallthepowersupplycover Ar...

Page 101: ...emovetheKnob 3 PlacethereplacementKnobonthepotentiometershaftwiththelocationofthepointerthesameasnotedinstep1 4 Tightenthescrewtosecuretheknobtothepotentiometershaft B ON OFF Switch SW1 Replacement 1...

Page 102: ...SqueezetogethertheclipsonthetopandbottomoftheSwitch thenremovetheswitchthroughtheFrontPanel 4 InstallthereplacementSwitchbyreversingtheabovesteps 5 Reinstallthepowersupplycover D POT LED PC Board Rep...

Page 103: ...ts forreplacement fusecatalognumber 4 Reinstallthepowersupplycoverbyreversingthestepsin paragraph B above Art A 03002 Fuse Location InternalFuseLocation B Work Cable Replacement 1 Removethepowersupply...

Page 104: ...wofconnectorslabeledLtowardtherearofthePowerSupply Fasteninplacewiththehardwareremovedpreviously 7 Completethewiringconnectionsasshown NOTE It is important that wires are installed correctly as shown...

Page 105: ...not be allowed to pick up any foreign material A very clean installation between the module and heatsink is essential for proper operation 1 Removethepowersupplycover 2 TurnthePowerSupplyontoitsside...

Page 106: ...1 9Nm CAUTION Failure to torque properly will cause component damage 11 Reconnect the wiring per the applicable chart From IGBT Terminals To Main PCB Terminals E28 E29 E13 E32 E33 E15 E30 E31 E35 J18...

Page 107: ...nputDiode 3 RemovescrewssecuringBoardinplace Removeboardanditsscrewsfromthepowersupply 4 Useisopropylalcoholandacleanragtocleanthemountingplate Removeallresidueoftheoriginalthermalpad Donot scratchora...

Page 108: ...roperly will cause component damage Art A 03908 Input Diode Input Diode Mounting Plate Thermal Pad E14 E16 E8 E6 E18 E13 E5 9 Reconnect the wiring per the chart E5 E1 E13 E2 E18 E3 E6 E8 E11 E6 E8 E11...

Page 109: ...tepsabove ItmaybeeasiertoinstallthePCBoardifthePowerSupply isturnedonitsrightsidefirst Torquethescrewsto17inch pounds 1 9Nm Art A 03909 Auxiliary Transformer IGBT Output Diode Attachment Screws 1 3 9...

Page 110: ...emovetheInputPower Cablefromtheunit 5 InstallthereplacementInputPowerCablebyreversingthe abovesteps TheInputPowerCablegroundwirerequiresa ringterminal Refertotheillustrationsforwireconnectiondetails F...

Page 111: ...screws must be installed with a star washer d LineuptheFanholeswiththescrewholesintheFanShroudthenattachtheFanbyinstallingtwoscrewsinopposite corners B Pilot PC Board Replacement ThePilotPCBoardmount...

Page 112: ...rmeranddisconnectwireconnectorontheCoil Winding 9 RemovetheTransformerfromtheunit carefullyguidingalltheconnectedcablesandwiresasyoudoso 10 Turnunitontoitsleftside 11 PositionthereplacementTransformer...

Page 113: ...theunit 8 Reinstallthepowersupplycover E Pressure Switch Solenoid Assembly PS1 SOL1 Replacement ThePressureSwitchandSolenoidValveareoneAssembly 1 Removethepowersupplycover 2 Disconnect a Wires 9and 10...

Page 114: ...ittingandpullonthetubetoreleaseit 4 RemovethenutsecuringtheFilter RegulatorAssemblytotheRegulatorMountingBracket RemovetheFilter Regulator AssemblyfromtheMountingBracket 5 InstallthereplacementFilter...

Page 115: ...nts Section 6 15 Torch Options Accessories NOTE Parts listed without item numbers are not shown but may be ordered by the catalog number shown B Returns If a product must be returned for service conta...

Page 116: ...FilterAssembly 9 7527 1 First Stage Cartridge 9 1021 1 Second Stage Cartridge 9 1022 1 Extended Work Cable 50 ft 15 2 m with Clamp 9 8529 1 Multi Purpose Cart 7 8888 1 25 7 6 m CNC Interface Cable 9 8...

Page 117: ...External Replacement Parts Item Qty Description Catalog 1 1 Coverwithlabels 9 7999 2 1 Tube rollhandle 9 8320 Hardware A 8 Screw 10 32x1 2PPHSwageform SeeNote1 B 4 Washer 1 4ExternalStar SeeNote1 C 4...

Page 118: ...Parts Item Qty Description Ref Catalog 1 1 Knob Fluted Skirted 0 250I D 9 8527 2 1 On OffRockerSwitch SW1 8 3258 3 1 Run RapidAutoRestart Set Switch SW2 8 3259 4 1 Assembly Pot LEDPCB 9 8004 5 1 Cable...

Page 119: ...Manual 0 4640 6 5 PARTS LISTS 6 This Page Left Blank...

Page 120: ...lPad 2 Externalstarwasher 2 Screw 8 32x1 2 PPH 4 1 PCBAssembly Logic 9 7996 5 1 PCBKit IGBTCircuit 9 8540 1 RoundThermalpad 6 1 PCBKit OutputDiode 9 8539 1 RoundThermalpad 7 PCBKit MainPower 1 For208...

Page 121: ...Manual 0 4640 6 7 PARTS LISTS 6 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 122: ...ion Catalog 1 1 Assembly Filter Regulator 9 7514 2 1 Regulator FilterReplacementElement 9 4414 3 1 RegulatorMountingBracket 9 7589 4 1 InputPowerCable For208 230 VoltUnits 8 4384 For400 Volt Units non...

Page 123: ...Manual 0 4640 6 9 PARTS LISTS 6 This Page Left Blank...

Page 124: ...9 8560 6 1 Automation Interface PC Board 9 4894 7 1 Automation Interface Wire Harness 9 4895 8 1 Transformer only in power supplies connected to SL100SV Torch 9 9449 with solenoid on mounting tube Har...

Page 125: ...Manual 0 4640 6 11 PARTS LISTS 6 NOTE Illustration may vary slightly from unit Art A 07119 2 3 4 5 D A E A B A 1 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 6 7 Heatsink 8...

Page 126: ...eads Assembly with ATC connector 4 7853 7 1 11 279 mm Rack 9 7041 8 1 11 279 mm Mounting Tube 9 7043 9 1 End Cap Assembly 9 7044 10 2 Body Mounting Pinch Block 9 4513 11 1 Pin Mounting Pinch Block 9 4...

Page 127: ...Manual 0 4640 6 13 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 128: ...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...

Page 129: ...Manual 0 4640 6 15 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 130: ...g 40 Amp Automated Machine Torch Spare Parts Kit includes 5 0054 3 Electrode 9 8215 5 30 Amp Tip 9 8206 5 40 Amp Standoff Tip 9 8208 1 Starter Cartridge 9 8213 1 Shield Cup Body 9 8237 1 Shield Cap Ma...

Page 131: ...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 To...

Page 132: ...PARTS LISTS 6 18 Manual 0 4640 6 This Page Left Blank...

Page 133: ...tem 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 Resta...

Page 134: ...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 135: ...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 136: ...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 B Power Supply and SL100SV Torch With Solenoid ATC Female Receptacle Front View ATC...

Page 137: ...d 1 2 5 4 3 7 6 8 White Black Orange Green Main PC Board Solenoid Torch Leads Torch Head Not Connected Not Connected Main PC Board Main PC Board Automated CutMaster Power Supply with ATC Torch Recepta...

Page 138: ...e 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 Ali...

Page 139: ...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 Automation Interface Switch Setting Chart Common Voltage Divider Output Settings 0 DOWN OFF 1 UP ON S...

Page 140: ...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...

Page 141: ...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...

Page 142: ...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 3...

Page 143: ...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...

Page 144: ...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 3...

Page 145: ...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...

Page 146: ...Automation Interface PC Board Pilot Board Art A 03789 Rear Panel CPC Connector Automation Interface PCB Connector J1 Automation Interface PCB Connector J4 E25 E26 E24 Main PC Board E23 8 7 6 5 4 3 2...

Page 147: ...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 C...

Page 148: ...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...

Page 149: ...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 A r c V o l t s N e g a t i v e R e m o t e C u r r e...

Page 150: ...dSignal J1 17 LogicLow DCOKSignalfromLogicPCB J1 18 LogicLow OVERTEMPsignalfromLogicPCB J1 19 LogicLow ACOKsignalfromLogicPCB J1 20 Return J1 21 LogicLow torchswitchsignaltoLogicPCB J1 22 12vdctoLogic...

Page 151: ...Low J4 5 28VACMainContactorW1 J4 6 28VACtoMainContactorW1 J4 7 12V J4 8 GroundfromPilotBoard J4 9 CurrentSensetoPilotBoard J4 10 ISensetoPilotBoard J5 1 28VACA fortestonly J5 2 Ground fortestonly J5 3...

Page 152: ...onal 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 04222 E...

Page 153: ...onal 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 E5 Art A 0422...

Page 154: ...APPENDIX A 22 Manual 0 4640 A APPENDIX 21 LOGIC BOARD LAYOUT Art A 03883 TP6 D8 TP1 TP8 TP9 TP10 TP3 TP4 TP2 TP5 TP7 P1 1 to P1 36 P1 7...

Page 155: ...cLow OVERTEMPSignal toMainPCB P1 19 LogicLow ACOKSignaltoMainPCB P1 20 ReturnforTorchSwitch P1 21 LogicLow TorchSwitchSignal P1 22 12vdc P1 23 ToCurrentControlPot P1 24 CurrentControl P1 25 CurrentCon...

Page 156: ...fromMainPCBoard J27 3 PotLow J14 4 12vdc J27 4 J14 5 LogicLowSignalforACOKIndicatorfromLogicPCBoard J27 5 J14 6 LogicLowSignalforGASIndicatorfromLogicPCBoard J27 6 J14 7 LogicLowSignalforTEMPIndicato...

Page 157: ...Manual 0 4640 A 25 APPENDIX A APPENDIX 23 OUTPUT DIODE BOARD LAYOUT A 02853 E37 E36 E38 E40 E43 E42 E39 E41...

Page 158: ...oAutomationInterfacePCBoardJ1 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 NotUsed E58 ToPow...

Page 159: ...Manual 0 4640 A 27 APPENDIX A APPENDIX 25 INPUT DIODE LAYOUT Art A 03882 E18 E13 E14 E5 E16 E8 E6...

Page 160: ...NDIX 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 Te...

Page 161: ...Manual 0 4640 A 29 APPENDIX A This Page Left Blank...

Page 162: ...5 24 21 22 23 26 8 6 7 1 4 5 2 3 8 6 7 1 4 5 2 3 28VAC B 28VAC A 1 4 2 3 2 1 4 3 5 6 4 1 2 3 4 1 2 3 3 4 8 7 6 9 10 1 5 4 3 2 12V CSR ISENSE 11 12 10 9 7 8 20 13 14 19 8 6 7 9 10 1 4 5 2 3 B A 1 2 3 T...

Page 163: ...SOR INDUCTOR OUTPUT INDUCTOR MAIN TRANSFORMER AUX TRANSFORMER FUSE 6 10A 600V KTK FAN 4 5 220VAC PRESSURE SWITCH GAS SOLENOID SWITCH ON OFF SWITCH RUN SET RAR W1 L1 T1 F1 SW1 SW2 M1 PS1 SOL1 T5 TS1 TS...

Page 164: ...19 8 6 7 9 10 1 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...

Page 165: ...CATION 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 I...

Page 166: ...CONNECTION CONFIGURATION 400V CE VERSION INCLUDES IN LINE EMC FILTER ISENSE CURRENT SENSE RTN CURRENT SENSE RED 12V GATE DRIVE B RTN GATE DRIVE B GATE DRIVE A RTN GATE DRIVE A CSR ISENSE FILTERING R9...

Page 167: ...PCB BLOCKS IS FOR REFERENCE ONLY DLL 05 27 03 GND 12V ISENSE CSR TOROID INSTALLED ON 400CE ONLY F5 1 2 8 5 E62 E58 E38 E39 E40 E41 E36 E37 E42 E43 E28 E29 E32 E33 E30 E31 1 1 2 2 5 8 9 7 OK TO MOVE LO...

Page 168: ...SENSE RED 12V 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...

Page 169: ...E 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...

Page 170: ...diagram new schematics Added Publication History to manual Mar 29 2006 AA Dropped references to leads extensions Changed to new cover style April 17 2006 AB Changed input diode torque spec to 35 in lb...

Page 171: ...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 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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