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TROUBLESHOOTING

4-14

Manual 0-2957

4.09 Main Arc Problems

Locate your symptom below:

A. Main cutting arc will not start

1. Work cable not connected.

a. Connect work cable.

2. Holding too high of a standoff.

a. Refer to recommended standoff heights. Adjust

as needed.

3. Workpiece is painted or rusty.

a. Clean workpiece.

4. Faulty Main PC Board or Logic Board.

a. Measure for ±0 vdc at TP2

to TP1 on the Logic

Board when attempting to transfer. Refer to
Logic Board Layout.

• If voltage goes to 0 vdc replace Output Board.

• If not, replace Main PC Board.

5. Faulty Main Input Contactor.

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 amps, circuitry in the power supply au-
tomatically reduces output current to 40 amps if
the torch tip contacts the workpiece.

. Faulty Pilot Board

a. With power off and wires E58 and E62 discon-

nected from the pilot board, measure for conti-
nuity between terminals #E58 and #E62. If con-
tinuity is found, replace Pilot Board.

Art # A-03651

INPUT
DIODE

E22

TP1

E15

TP4

J24

J32 J29

E10

E20

J30

E33

J18

J26

E27

J23

E30

J33

J31

E23

E32

J27

J25

IGBT A

IGBT B

J43

J34

J11

J15

J16

J17

FUSE

Main Printed Circuit Board Layout (logic board not shown)

Содержание CUTMASTER 81

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

Страница 2: ......

Страница 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...

Страница 4: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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